Looking at grille block options for the HCH
 

I am ready to make a grille block for the HCH. I am trying to decide how i want to go about it. Here is a pic for reference...
http://i663.photobucket.com/albums/u...psrqirhhwl.jpg
Now my preference is to go clear across the front, fog light to foglight with a 1 piece block. I feel that would be the "cleanest" way to go. I am probably going to use white sheetmetal for the block. I have some sheetmetal at work that is big enough to make individual blocks for the front. Are we looking at a big enough difference between a 1 piece and individual blocks? On the HCH the H on the grille is actually an air duct that allows airflow. The lower slit in the "grille" is also airflow. The area under the chrome strip is just merely for decoration and drag, it dead ends to nothing, so I am going to find a solution for sealing that up. I am hoping by leaving all the upper grille area open I can get sufficient airflow for cooling. Also, with fall temps dropping, hopefully that will work in my favor also.
So thoughts on the best plan for my air blocks?

Rob

Well, I got froggy and made some small grille blocks. I am going on a trip this weekend, so we will see how things happen.
If I can get a bigger piece of sheetmetal I am going to make a one piece grille block and really try to make a nice super smooth front bumper. I have driven it the last to afternoons with cranking and no temp problem.
http://i663.photobucket.com/albums/u...psh3qrzxhe.jpg

http://i663.photobucket.com/albums/u...psgplgicnn.jpg

Well here is to aerodynamic modifications!

Could you describe how did you mount them?

I just used some screws i had on hand. They were screws for mounting sheet metal to wood framing. I just screwed the metal panels to the plastic bumper cover. If you look carefully you can see the screws. 2 on the outer covers, 3 on the middles.

notahippee, do you have a way of accurately monitoring the coolant temperature? The factory temp. gauge on that car hits mid way at around 164 and stays there well past 200.

Block looks good.

My scientific way of dealing with coolant temp is to open the block a bit if the fans come on at stop lights. I find that you can usually get away with a full lower block off peak summer temps. They were designed for worst case scenario: Death valley mid July, fully loaded, driving up a steep hill. Still, a coolant temp gauge is much preferred.

Well we clocked almost 400 miles this weekend. No sign of overheating and the ac never missed a beat. I feel that we are good with air flow. Now I need to fix the IMA, because 35-40 mpg is not cutting it!