SO I done a rather basic grill block out of cardboard, painted it black and set off on my journey, engine temp was a little higher than usual but nothing to cause alarm, but there was a burning smell and smoke coming up from the bonnet. I pulled over and everything seemed ok, but I took the grill block off just to be safe.
A short while later I think I understood what the problem was. It was the lower grill and it was a 100% block. This is where my turbo intercooler is so I think that must have got crazy hot and maybe it was the pipes smouldering.
So where does that leave me? It has tiny upper grill anyway so I can't see much aero advantage in blocking it off.
Question is, how do you folks with turbo intercooler grill block? Or is my intercooler shot as it is getting too hot too easy?
PS, that was overheating without even using the turbo as I drive so gently the turbo never kicks in at all.