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For the molding problems, if there is a good market for this, I would think buying a OEM grill and remaking it solid so it is an actual replacement would be the simple way to do it. Would have to paint to match color etc, so 300+ cars with 10 colors each would be a lot of stocking problems if it was done for all cars. I was thinking just a few select cars at first to see if there is interest. I have seen some people here with great fiberglass skills, so I think that would be one of the requirements for the business owner to start the business.
Just a couple quick examples of cars that can use a grill block with no problems would be a 1992-1996 (and 1997-2001) Toyota Camry, and the 1993-1997 Toyota Corolla. Both car models have a fairly small top grill that is also easy to change. If I could buy a grill block for my corolla that looked OEM, I would jump all over it if the price isn't too much. Buyer's view is that it must benefit their wallet for the price paid though.
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