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Old 12-16-2014, 07:09 PM   #51 (permalink)
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Look what I did to my Insight...
A black grill block would not look right on the Insight with its metallic grey bumper plastic whateveritis.

So I took out a sheet of lexan and a fake Dremel and wasted some cutting discs to produce this:


I cut a hole for the emblem cause that's where the outer temp sensor is.

This is not the final version. Lacking time I just taped it into position, but I've saved the lining from my bashed windscreen (rogue hubcap) and may well use that to line the bottom and side edges. Either that or some silicone.
Then I've got some LED strips to set behind it for DRL's... We'll see.

Up to now it holds and does indeed kick up the coolant temperature within the desired range (82C to 92C; that's where the thermostat that governs coolant flow to the radiator is half open).
Come hotter times I can remove the foam pipe tubes in the lower grill one by one.

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Last edited by RedDevil; 12-16-2014 at 07:15 PM..
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Old 12-17-2014, 01:12 AM   #52 (permalink)
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Very nice! I like that you decided to keep laminar flow by making it flush with the front edge of the bumper.

Can't wait to see the final version!

I recently discovered this on amazon and am considering using this to attach future mods

3M Automotive Acrylic Plus Attachment Tape - 1/2in. x 20 Yard Roll, Model# 06382 https://amzn.to/2JIvEyw
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Old 12-17-2014, 04:38 AM   #53 (permalink)
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It is three times as expensive as the plate I used for my grill block but a good product, no doubt.

I want to make a small frame or set of mounting points from an aluminum strip I bought a while ago, or maybe a couple of studs to the grill with washers behind the slits.

I may need to remove one foam pipe from the lower grill as I saw the intake temp go up as high as 39C (in 5C weather), which can reduce EGR usage.
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Old 12-17-2014, 08:09 AM   #54 (permalink)
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I used the rear spoiler from my kid's 90's Subaru Legacy wagon for my lower grill block. I had previously used it as a flat detached wing on Black Widow before I bought the kammback.

Time spent: fifteen minutes (including the flat-black paint job)

Cost of project: Free! Already had all the materials on hand, and the paint was left over from painting the Black Widow back in the day.

Best part is that it looks so legit that my wife never even realized I had snuck in another exterior mod on Turtle! I finally told her about it, and then I had to actually point it out to her before she saw it!
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Old 12-17-2014, 10:26 AM   #55 (permalink)
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The 3M tape is good stuff. We stock it in a few widths to make problems go away.
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Manual neutral engine off.100% @MPG <----- Fun Fact.
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Old 01-05-2015, 06:24 PM   #56 (permalink)
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Version 1.1 of my Lexan UGB:


Version 1 was scoring the plastic underneath, despite my attempt to round the edges.
I tried to make it fit better (not really successful as you can see).
I covered the edges with double sided sticky tape which both protects and locks the lower edge.
The upper edge is held by 2 inch wide clear tape for the whole width and extending over the headlights.
I can live with this for now.
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lifetime FE over 0.14 Gm or 0.09 MM.

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Old 01-05-2015, 06:30 PM   #57 (permalink)
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Much improved! It contours the edges much better now.

If you ever really get anal with the looks, perhaps fill the corner gaps with bondo putty and sand it to match the contours of the oem bumper.

Then perhaps only paint the bottom 1/3 of the upper grill block to blend the bondo and lexan. That way, you can still see the upper 2/3 of clear lexan.

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