DIY Project 63

Making a Custom Mesh Grill

by Ilanpro (Difficulty: hard)

Tools Required
Dremel w/Cutting Disc
Metal shears
Sander
Glue Gun

Materials
Stock Grill
Mesh
Fiberglass Resin & Mat
J&B Cold Weld
Bondo
Sandpaper (750Grit- 2000Grit)
Duct Tape

The Project:

1. Remove grill from car.

2. Cut the inner part of the stock grill. Gutting it completely.

3. Apply duct tape on the finished side of the grill (middle) covering the notches.

4. Mix and apply the J&B weld thru the underside of the grill. Note: Take your time! J&B Weld can be somewhat slippery. Let it dry for 24 hrs.

5. Remove tape

6. Cut the fiberglass mat to size of the notches then use the fiberglass resin and completely saturate the mat.

7. Take each piece of mat and cover the notches on both sides with only one piece then let dry for 24 hrs.

8. Go over the whole grill where the notches were and brush fiberglass making the whole side uniform then let it dry for 24 hrs.

9. Using the heavy grit sand paper on the sander start sanding the side to be finished, making it as even as possible.

10. Clean it well and start applying bondo (use the fiberglass type) Don't make it too lumpy to make sandding easier. Let it dry for 5 hrs.

11. Start sanding until is completely level, WARNING you may have to apply bondo again.

12. When you are satisfied that is really smooth go down to a 1200 Grit sandpaper (wet sand) and sand some more (byhand). Then finish sanding with the 2000 Grit (wet sand). Wash the grill.

13. When dry, double check your work if confident go ahead and primer. When the primer is done look for grooves and lines... if any, sand some more until the primer show smooth.

14. Two coats of primer.

15. Three coats of color.

16. At this point using the shears, cut the amount of mesh to cover the center of the grill leaving some slack to bend on the rear side (to attach it).

17. When satisfied with the fitting go ahead and bend the slack hugging the back side of the grill and secure with the glue gun

18. Four coats of clearcoat going over everything including the mesh.

19. Let it dry and your done.

- ilanpro

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Notes from GT Man: While this project was done on an '04 GT, it can be adapted to earlier model Elantras. This is a very difficult, time consuming project. If you have any doubts on this one, have a pro do it!