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Old 08-27-2013, 10:51 AM   #1 (permalink)
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Join Date: May 2010
Location: Texas Coast, close to Houston
Posts: 880

getto - '02 Volkswagen Jetta GLS TDI
90 day: 53.82 mpg (US)
Thanks: 413
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02 TDI Jetta grille block

i am hitting between 55-59 inst mpg(ultragauge) compared to 49-53, no drafting, flat concrete interstate(conditions were the same, as best as i could get them). stop n go, ac on, rain, temp climbed to 210 but fell to 197, where it stays while cruising. fill up yesterday but forgot to clear trip odo so will have to wait till next tank bc i can get over 900 mpt.
using silicone, placed 3 larger than opening pieces of coroplast together, held down with cans on flat surface.
removed grille.

marked areas to remove, using grinder with cut off wheel, removed/beveled sections to fit.

added salvaged wiper strands into slots and added a rear support to prevent deformation.

added 2 more pieces to bring it close to flush, adding spacer to form curve.

silicone/tape was used to attach/seal/hold edges.

bent plate , relocated to center bumper, held on with silicone after this pic.

needs some fine tuning around edges of last layer.
so far so good.
no finished pic but will get one later to show contour of leading edge.

FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

Last edited by deejaaa; 08-27-2013 at 03:59 PM.. Reason: who knows......
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