Astra Grill Block

[aearles]

Hi guys, first post here - your forum has inspired me to start with some winter mods for a little better fuel economy out of my Saturn Astra 1.8L, I average about 28MPG throughout the year, but during winter it gets down more towards 24MPG so I'm looking at building a Grill Block and adding a block heater, and I'm hoping to get some recommendations from the pros on the grill.

I've already created a cardboard template of both the upper and lower grills, and I just picked up a half sheet of Coroplast from a local sign shop, I just need to know what you guys think of blocking the top vs bottom on my car, it looks like most recommend blocking the top, and then possibly some of the bottom on most cars, but because on my car the lower grill is so much bigger than the top, I thought maybe I should go the other way around.

I've posted a picture below, please let me know what you think. Also, what are you guys using as fasteners? I would like to only run it during the winter but have it easily removable and replaceable instead of using zip ties etc, and of course I want it to look clean.

Let me know what you think, thank you!

(oops, cant post images/links yet, please replace the hxxp)



The top slot of the top grill (above the saturn logo) looks open to under the hood, but it's not, it seals up tight to the hood a few inches in, creating kind of a parachute cavern space...

[Daox]

I'd still block the top... and most of the bottom if not all of it.

Is there a piece of plastic between the bumper cover and the main frame member of the front of the car? If that is open, I would block the entire front grill. I did this with my Toyota Matrix and it worked very well in winter.

[aearles]

Not sure, I'll get out there and look tonight.

What were the fasteners that you used on yours? They looked great.

[Daox]

The one with the wood blocks? The blocks are held together with stainless deck screws and I just use a button head stainless screw and fender washer to hold the grill block on.

The previous method just used 10-32 thumb screws and wing nuts. It worked alright but did loosen up in spring.

[Daox]

Here is the new and IMO better way if your grill is recessed. The thumb screw way works good for flush mounting.

http://ecomodder.com/forum/showthrea...hod-15335.html

[aearles]

I meant these: http://ecomodder.com/forum/showthrea...html#post38045

[Daox]

Ah, yeah. That method works good if you want to mount the grill block flush with the grill. If you grill is inset like most lower grills are, the wood block way works great.

[aearles]

Yeah, my lower grill I will use blocks, the upper I was hoping to use a similar plastic (?) fastener like yours, where did you get those and how do they mount up from behind?

[Daox]

I did the same type of block on my Prius. I got a picture of the fasteners I used. They're just thumb screws, fender washers, and wing nuts.

http://ecomodder.com/forum/showthrea...tml#post143460

[aearles]

Oh perfect, simple enough. You rock, thanks for the help!