Time for a grill block. I used the left over scraps from the air dam on this. btw the air dam material is abs plastic. i bought a 4' x 8' sheet 1/4" thick, cost $80 for whole sheet. I made 2 air dams with the sheet and now a grill block. i used an angle grinder with a cut off wheel to cut and then a grinder wheel to shape and fit. also used a heat gun to mold it into shape. very stiff stuff, but if you heat it you can work with it pretty easily.
Thinking I might use black silicone around all the edges to keep air out of cracks, but still looking around for options on a material for this. Please let me know what has worked well or not so well for you.
