[butchgibson]

Not much data to start with or to end with, but I've seen folks use cardboard and plastic for a grill block project. I used discarded white board material. I've realized that sometimes folks buy a white board and either return it to place of purchase or just throw it out after someone uses a permanent marker instead of a dry erase marker. Since it is white and my Geo Metro is white, I thought I'd experiment with a grill block. I used some tin snips, a hand saw, and a drill to rough cut a piece of white board based upon an original pattern created from plastic. The final outcome is not airtight but took about 10 minutes and bolted right on (or screwed right into place) using existing bumper mounting screws. Just thought I'd share. No mileage data at this point. Haven't been recording any, but just needed to get another vehicle running in the family and thought I'd be the one to drive and work on this 1991 Geo Metro.