[Christ]

Originally Posted by Sean T.

I decided to go with Jim's idea for my (first) attempt. It took about 3-4 times of lining up the cling wrap before I got it to line the grille with a good seal so the foam wouldnt get on the paint. It's drying right now but here's a pic of it while it's drying.

In fact, it's expanded quite noticeably since I took the pic about 10 minutes ago. The can says it fully sets after 8 hours... so I probably won't have any updates until tomorrow.

Keep in mind, I don't think you can cut that stuff with a hot knife. I'm relatively sure you'll have to rough shape it with a saw, then sand/smooth it. Also, when you cut it, it loses its waterproof skin, so you'll have to add something to the face of it so that it doesn't absorb water.

You may be able to just apply some bondo and paint match it with some touch up paint.