I started work on the grille block. One nice thing about the design of the grille on the Sonoma is that it just pops right off the truck. And thanks to my wonderful wife, I was able to work on it inside where it's nice and warm.
Basically I built a form from bits of a pizza box, aluminum foil, and painter's tape. I first attempted this with plastic wrap, which was a lesson in failure. I left a partial opening at the top above the logo and sank two bolts into the form so that it can be secured (and removed later for the summer if necessary).
Now I'm just waiting for the foam to cure... directions say four hours but I'm guessing it will be closer to twelve because of the thickness. I'm planning to check it much like a cake - stick a toothpick in and see if it comes out clean.