2006 Focus ZX3 "Blueberry" Build
 

I finally started to put some decent semi-permanent grille blocks on the focus last night.

My upper block is composed of a poorly trimmed piece of insulation foam and some packaging tape, that will need to be addressed in the future, but I was mainly trying to figure out a cost-effective material, and I don't know why but I didn't like the coroplast idea. Luckily, I work at a body shop, and we regularly throw out plastic bumper covers that are usually 90% intact, so I stole one and chopped it up for materials.

Using the tried-and-true cardboard template method, I whipped up some fog lamp covers, and also covers for the outer portion of the lower grille, only covering beyond the sides of the radiator. This is meant to be the permanent portion of the grille block, and the part closer to the center will have some experimentation with a removable/variable option.

I attached them with aluminum pop-rivets using washers behind the cover to give them something to grab onto, and I will be using either some silicone, or (if I get ambitious) some actual body filler to smooth out the sharp edges of the covers.

Honestly, I'm pretty happy with how these turned out, excited to do some driving and see if I can perceive a difference in coast time.



P.S.

For anybody like me who is struggling with finding a suitable, cheap material, most body shops will have GOBS of garbage automotive plastic and sheet metal parts they are throwing away, or even PAYING to dispose of. If you go into your local Bondo Bob's and say please, you can probably get away with some free, recycled material to tape to the front of your cars!

Any update on your mods? Since you have a lift you may consider a smooth underbody, except for exhaust openings.

No update yet, I've only put on about 150 miles since the grille covers, and it has been to erratic of driving conditions to confirm any difference.

I definitely plan on doing a smooth underbody, just trying to take care of some other life projects right now, but I've been brainstorming, trying to sort out the best way to attach a smooth underbody.