Grill Block for Ford Ranger
 

Okay so I want to start my first modification on my truck and decided to do the grill block. I just looked at my grill and it's a massive hole! How do I even attempt blocking anything like that?

I've also seen a lot of threads with owners running mock ups before making something more permanent. What materials would be good for the job? And can you explain it in smaller words so the new guy can follow? Sometimes I think I need a chemistry degree to know what is what.

Try black duct tape for starters and if you see positive results then start thinking about something more permanent that also looks good.

I tried using cardboard then tape over it. if you like how that works then you can make one from metal or coloplast.

I first tried cardboard. It lasted about an hour, because the rain started right after installing the cardboard. Cardboard grille blocks are like rain dances that actually work.

Then I used part of a roll of two inch wide masking tape. That worked well enough to show proof of concept, but was ugly to look at.

Then I put on a piece of 3M window film. I used the exterior grade because it's twice as thick as the interior grade. The original window film has been on for almost two years now.

Okay, so I acquired some pretty hefty cardboard and I got some materials to waterproof said cardboard. My question is now, what is the most effective way to stencil the shape onto the cardboard so I can cut out the insert?

Just cut a piece that is too large. Then slowly trim until it fits.

Okay, so I lost my patience with the cardboard in less than half an hour! So I just used some handy-dandy 100 MPH tape, that's green duct tape to those not in the military. So the entire grill is covered and the only opening that is left is the one in the bumper. I noticed that there are two horizontal depressions, one above the Ford decal and the other below, that correspond with a head light to head light gap in the grill. The gaps to the left and the right of the decal are not noticeable so I will find a way to support the top and bottom gaps, I still have plenty of cardboard, for phase 2 of the project.

Any advice?

Can you post a couple of pics?

Here you go, sorry about the delay! Don't tell Apple, but my iPhone4's camera doesn't work! Have to borrow the wife's.

So my FWT on the good old scangauge is barely hitting over 200 on my 20 mile daily commute, but if I go about 6 miles, from my house to my wife's work, the engine isn't even warmed up! SG is saying 40 MPG to my work and 30 MPG to her work, and a good chunk of the trip is IDENTICAL!

I'm thinking more of that duct tape to cover the lower opening for the radiator; let's just use the gaps in the body work to cool it down. Anybody have any advice?

I think if you put on enough grill block to get it to 200 deg F within maybe 4 miles or so, it will need the fan to keep from overheating once you get 10 miles down the road.

Does it have a belt operated radiator fan? If so, swap it out to an electric one. That will reduce air flow but the elec fan will kick in when needed.

Best way to switch it is with a temp switch in the LOWER rad hose. Set it 10-15 degrees cooler than the thermostat opening temperature and you're good to go. I experimented with every possible position and setting for a temp switch and settled on that as very workable. Then I ran into a performance car modder (Cobra!) who had done the same on his car, with never an overheating problem even with the big V8.

Grill cover material
 

You may try a 1mm thick plexiglass cover. Coarser is good if you don´t have to curve it.

It looks like it wasn´t there.

Hundred mile tape but it has to be generic? Oh. How about foam blocks that stay dry? Or Styrofoam TM . That would do the deal. You know how to make a Styrofoam cutter with guitar wire and a 12 volt? It looks like a harp with one string.

Rangers have two fans: 1) A mechanical fan with a temperature dependent viscous fluid clutch, and 2) An electric fan. The electric fan only comes on when the air conditioning is on or extremely hot temperatures. The mechanical fan runs all the time, but the clutch has a lot of slip at low temperatures, causing it to run slower. As the temperature increases, the clutch fluid gets thicker, causing more coupling to the fan and the fan runs faster.

After I blocked the upper grill of my Ranger, it appears I picked up about 1 mpg for local driving. I haven't done any real highway driving since I blocked the grill in May to see if my highway FE is any better. The engine temp, per Scangauge, has dropped from a typical 210 in the summer to about 204 since blocking the grill. A drop in temp would indicate that the fan is running faster. But the fan speed is temperature dependent and a lower temp should be a slower fan speed. The fuel economy has improved, indicating that if the fan is working harder, the aerodynamic improvement is more than offsetting the fan's power draw.

Oh I see I know all that srry. Did not get that at first. I think the friction or fan clutch is what the other thread forum member wanted a way to add a derailleur to a motor driven pedal car. The Ranger I had was a bit advanced older car with the 8 plugs and 4 cylinders. But it was years into advancement and the development cost was in the millions of dollars and 4 or 5 years to get into produce. It is a great ride and I think the mod might benefit with velcro like the other modders have been added.