How to - Almost OEM Upper Grill Block for 2013 Subaru Sti

[Keito]

Nice work.
I was reading this thread thinking I wish I could use our 3D printer here at work and
go into the grill block business.

[Vekke]

That looked quite nice on the pictures. However that is lots of work and takes skills to get smooth surface.

If you use 3mm thick ABS plastics that has etched surface you can make this kind block in a hour if you have praticed or about three hours if its your first time:


Upper block from behind...



Total looks of the car.

Beginners guide:
1. To shape the block first cut right size paper/carboard block
2. transfer the lines to ABS plastic with pen marker.
3. draw the line with sharp knife plastic on the floor. Once is enough.
4. Bent the plastic and it will break along the line
5. fit to the car and fine tune cutting off small pieces with knife. 1mm is easy but up to 3mm if you have sharp knife and right technigue.
6. mark ziptie positions with pen marker
7. drill 5mm holes
8. Make about 50mm hole for outside temperature sensor
9. Install and enjoy

I just measure and build without template and it looked like that with first try .

[hockey3592]

Any updates to the mods and your averages?

[tf4624]

so the original poster:

no issues with cool down? with the radiator?

[jedi_sol]

I monitor my water temp gauge via the torque app

Normal running temp: 186*F
with grill block: it fluctuates between 188-205*F

the cooling fan on the sti does not kick in until 215*F.

No overheating issues thus far!

[justme1969]

I dont want to hijack the post but The ABS if reinforced may just be an answer for my rear wheel skirts. I want them to precision flush mount into the opening, but be easy to remove for tire failures. Cutting a few zipties is a better answer than ive been contemplating so far; and much cheaper than push pins.

[Topdawg_135]

Looks great! I did the same with mine last summer. I had issues when it came down to the final shaping. Luckily USC Icing does a great job of filling pinholes.

[jedi_sol]

the perfectionist in me is still unsatisfied on how my upper grill block came out....its too bulky, heavy and "wrinkly."



I'm getting better at fiberglassing now and learned that the better i prep in the beginning, the better the result.

For version 3.??? i lined the outer edges of the upper grill opening with double sided tape and tightly wrapped a tshirt around the whole thing. This way i should hopefully have clean edges, no sagging, no need for expanding foam, and minimal sanding. I'm also putting on more layers of resin for strength so that it should not crack when i remove the grill block from the grill.

[jedi_sol]

Resin came out pretty smooth, I shouldn’t need to sand it that much


I also bought myself a rotary/dremel too (my first power tool!) to let me get some really nice details around the Subaru emblem.

[Daox]

Looks good. If you want to make it really smooth spray a guide coat (super thin layer of a different color) on it and sand it down to see your high/low spots. Fill in the low spots with some body filler.