DIY: Mesh Grille (lower) - Chevy Cobalt Forum / Cobalt Reviews / Cobalt SS / Cobalt Parts
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post #1 of 6 (permalink) Old 03-08-2009, 01:17 AM Thread Starter

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DIY: Mesh Grille (lower)

So this is just an extension on Nugz post on how to do the mesh grille. I was bored one day and took my bumper off to get at a few other things and while I was at it I figured I might as well take the lower grille off and make it mesh. So heres how I did it along with a few photos.

So to Start off with I removed the bumper (prob could do it without removing bumper though) and on the Lower grille their were several clips in behind you have to pry out then it just slides right off.

Me with the bumper off. Was taking pics with my web cam for new facebook profile pics :P

Next I used a small saw and cut off all the inside plastic blades.

me demonstrating cutting

Then useing a dremel with a grinding tool ( which I accidently wore all the way down doing this) I grinded the areas where the blades attached down to be even with the surface then used the sanding tool to make it all smooth. (note the safety goggles, safety first! but actually while you grind/sand it the small pieces of plastic fly everywhere fast so be sure to use goggles)

Next I washed the entire plastic piece in warm soapy water to get all the dust and stuff off from sanding.

I then dyed it well in the sun ( has to be dry for painting) then painted it the colour of my choice.

Next onto the mesh while that dried. I used just regular plastic gutter mesh I found in the cupboard, I simply took it layed it out and painted it the colour of my choice also.

Next was the hardest part, after drying I set it over top of the plastic border and cut it to the dimensions I needed, then used twist ties and fishing line and elastic bands to get it to stay in place while I glued it, I used this water/weatherproof flexible glue stuff I found at the hardware store, when it dried it was like a silicone type material.

lastly I left it to dry then put it onto my car the next day
Heres some final pics the first one was in my garage after putting it in and the
2nd was when I was over at a friends house helping him with his car I was bored so I took a few pics.

So let me know what you think and hows it look on my car?

Problems I had:
-Mesh was kinda too flexible so u need to get it cut just right to not 'fold' inwards on itself if you understand what i'm saying.
-when gluing it was hard to small clamps would work to help this
-when i put it back in the car it did not fully fit in as before for some reason, it had a small gap in the top between plastic and the bumper so I had to glue it to the bumper their and clamp it for another night. It fit fine after.
-When grinding/sanding the bars are attached to the outside border with a cheap hollow V design so after cutting their are V cuts in the border where the bars used to be, might want to cover this with another plastic inlay inside the border or something, I just left it as its not noticeable and looks cools/interesting up close.
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post #2 of 6 (permalink) Old 03-08-2009, 10:38 AM
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Looks great man! nice how-to! Can you get some more close up pics of it? I may do this all the way around my LT since i don't have fog lights.

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post #3 of 6 (permalink) Old 03-08-2009, 11:17 AM
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that looks very good.

Repopulating one post at a time.

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post #4 of 6 (permalink) Old 03-08-2009, 10:13 PM
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Nicely done. I would like to see some additional photos as well.

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post #5 of 6 (permalink) Old 03-09-2009, 05:43 PM Thread Starter

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ill put some more pics up tommorow when I get a chance to put it in the sun in some good lighting, its at the glass place getting a window crack fixed.
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post #6 of 6 (permalink) Old 03-09-2009, 10:49 PM
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