The upper grill block also resides behind the grill, but this one is still made of cardboard. It looks like I'll need to remove the upper grill (or at least pop out a few bolts and move it a little) to make a more exact template of the hole for more edging material to be cut to order. It's doing the job well right now, but doesn't have the same look, or ability to withstand weather as it will in plastic
While I was hanging around the front of the car with my camera, I lay down and got a picture underneath showing the drastic need for a partial belly pan (at least).
I think I shall follow the herd on this one and go with coroplast (any local elections coming up?), but I am thinking some aluminum or sheet tin would be better closer to the hot bits. From those of you with experience with these things, would alum rivets be a good method for attaching aluminum to coroplast? or would they pull through the plastic over time? Perhaps washers to spread the load?