Ok before you guys kill me for never getting anything done and asking 50 billion questions... I have all the supplies for everything I have been talking about I just cant seem to get the ambition up to lay in the dirt in 85deg sun to do it.. I thank everyone here for the encouragement, openness to new ideas and the volumes of information you all share.
This is what I want the final product to look like. I did a quick photo editing job on a picture I had. The upper grill block is the real question here. Aside from aero do you think this works into the design well? The chrome surround will be removed on the real one leaving a small recess for the material to fit into nice and flush.
I bought some expanding foam to fill in the fog light holes so I can make removeable "plugs"