I was not completely satisfied with Upper grill block v 3.0 fitment and alignment
AWD180 suggested i heat it up and remold it...but the fiberglass/resin was too thick and would not re-mold. I decided to start on upper grill block v 3.1
I always see suggestions to "make a basic "frame" by doing a thin layer of fiberglass, then fill the void with greatstuff foam", however, i still have not seen anybody implement this yet. I like this method because now i can essentially make the grill block line up exactly with contours of the grill without risking sanding down the grill block itself.
The main problem i had with my grill block v 3.0 was that the "release agent" (plastic wrap / aluminum) became seperated from the grill because there ws nothing holding the actual release agent onto the grill. While the resin was drying, this causing the huge gap in the picture you see above.
Therefore, i found double sided tape duct tape from home depot and lined my grill so that the release agent perfectly conforms to the shape of the grill
Next up, applying fiberglass to make a basic "mold" of the grill," then fill the voids with greatstuff foam, then sanding and bondo.