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Old 04-01-2012, 12:11 PM   #4 (permalink)
Cyborg ECU
California98Civic's Avatar
Join Date: Mar 2011
Location: Coastal Southern California
Posts: 6,297

Black and Green - '98 Honda Civic DX Coupe
Team Honda
90 day: 66.42 mpg (US)

Black and Red - '00 Nashbar Custom built eBike
90 day: 3671.43 mpg (US)
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Originally Posted by bhut2180 View Post

My next step that I'll do is probably buy that expandable foam stuff, spray it in the wholes, cut and form it to look like what I have with the cardboard over it, then fiberglass over the foam. Once I get a good layer of thick fiberglass, Ill remove the foam from behind
The foam can work well. Make sure you let it cure for quite a while. Days. I have found it buckles, shrinks, and pits easily. I think Daox reported similar experiences in his "Pretty Prius Grill Block" project thread.

I suggest, actually, that you leave some of the openings in the lower grill in front of your cooling radiator. When the weather is warmer, you might regret permanently and irreversibly closing all those gaps. Duct the remaining openings directly to the radiator so all air entering the car is forced through the radiator. You might leave the fog light holes too, covering them with something removable. LED lights installed there could save battery life by decreasing use of your higher amp and wattage headlights in all sorts of twilight and weather-related driving conditions.

I'm looking forward to watching your progress!
See my car's mod & maintenance thread and my electric bicycle's thread for ongoing projects. I will rebuild Black and Green over decades as parts die, until it becomes a different car of roughly the same shape and color. My minimum fuel economy goal is 55 mpg while averaging posted speed limits. I generally top 60 mpg. See also my Honda manual transmission specs thread.

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