Front Grill block finished (mostly)
 

http://img.photobucket.com/albums/v4...FDE7C5D91B.jpghttp://img.photobucket.com/albums/v4...e/IMG_1401.jpg

So aside from needing a ton of hours of sanding and repainting to make it all smooth, I've basically finished off the front grill blocks. Its all bondo and expanding foam. I decided to make it permanent after figuring out the "hole size" with duct tape. Coolant temps never go above 206, and usually stay around 198-202 range.

All-in-all, I'd call it a success!

Wow, thats quite a bit of work. Nice job. Do you have any close up shots?

I'll post more close up shots after I've gotten a bit more work done with it... it's embarrassing the amount of sanding that still needs to be done.

You know what, I change my mind. I'll post more photos today. To hell with when I'll have time for more sanding. That could take a month!

Haha... yeah I know how that goes. :)

I often forget that there will be a lot less judgement HERE than I typically get from "normal" people.

I've put about 5hrs of sanding into it already, and I figure I've got AT LEAST 10hrs more to go. I need to go buy more sand paper...

Pictures:

http://img.photobucket.com/albums/v4...y/IMG_1400.jpg
http://img.photobucket.com/albums/v4...y/IMG_1401.jpg
http://img.photobucket.com/albums/v4...y/IMG_1402.jpg
http://img.photobucket.com/albums/v4...y/IMG_1403.jpg

It's gonna be nice when done. I like it better than OEM already. The upper looks great already.

That looks pretty darn good.

I don't know if you have one of these, or can make something similar out of a 1x4 or something, but when I was doing my pretty grill block it came in very handy.

Keysco Speed File Sanding Board — 17in. Long, Model# 77527 | Sanders| Northern Tool + Equipment

Well, I think I'm going to have to shift gears a bit. I've recently learned that Bondo doesn't work well with plastics like the front bumper. (I wish I would've known that!) So in the areas around the edges where there isn't any expanding foam and the bond is contacting the plastic it will separate and just cause a bunch of problems. I'm not sure how to proceed. I'm thinking fiberglass.

That's what I did, and it seemed to work well.

http://i1047.photobucket.com/albums/...528_171909.jpg

EXACTLY the result I'm looking for... Perfect! Thanks for sharing. I know what I have to do now.