It was very nice out tonight, so I decided to update my lower grill block. I had thrown this one in the car at the beginning of winter. It held up okay. It got a few holes in it and you can tell the cardboard was really starting to fall apart. So it was time for something a little better.
I went with a tried and true method of doing a grill block. I've used this method a few times on my Prius and it seems to work quite well. I use a block of wood as a spacer to push the coroplast out farther away from the grill slats. In this case, I drilled holes in the wood blocks and used zip ties to attach the blocks to the car.
After that, I cut up a piece of black coroplast, centered it and drilled holes for the screws to attach the grill block. Being coroplast, I used some fender washers under the screw heads to distribute the load.
It fits up pretty nice with a bit of gap at either end. I'm quite fine with that. It allows a bit of area if the fan does turn on from it to suck air from.
