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I just made a grill block for my Camry about 30 minutes ago and mounted it. Made it out of the pink insulation board ($10 for an 8'x3' sheet of half inch thick stuff). I used cardboard to make a template and then transfered it over to the foam board when I got it right. Then I just took sand paper to it to do the fine fitting part and then painted it to match my car with gloss spray paint...viola, done, 1 hour.
If I start seeing some decent FE gains from this and the belly pan I'm making, I'll be sure to put up pics and results as far as gains are concerned and I'm planning on attaching it more permanently as well. Right now it's held on with packing tape, which, oddly enough, not only is clear so it doesn't show up, but sticks to the foam better then duct tape which sorta surprised me, but I had to use it to cover some gaps that got made from a miss-cut and it stuck great, so I used it for the rest of it to hold it in place.
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