Lower & Upper Grille Block Ideas (Toyota Echo) - Page 8 - Fuel Economy, Hypermiling, EcoModding News and Forum

CigaR007 · 08-09-2011, 04:08 PM

Thank you for the kind words.

As you can see throughout this thread, my grille blocks have evolved and I see that as a leap forward in terms of design, fabrication and efficiency. I must admit though, this whole process is very time-consuming but it is fun, so it is worthwhile.

Currently applying the final coats of electric green mica on the upper grille block. It looks like it will be very stealthy once installed on the car.

graydonengineering · 08-09-2011, 04:31 PM

Looking great! I am thinking of doing something similar for my lower bumper. I was thinking of boxing off the slot to be pluged with plastic wrap all to make a sealed chamber and then injection expanding foam (such as Great Stuff) untill it is filled. Do you think this method would work? After that I would want to coat it and paint it. The resin coat looks like it is working well but labor intensive.

alohaspirit · 08-10-2011, 12:58 AM

excellent job ciga

ive been MIA from the board but keeping up with my gas log

unfortunately no grill blocks can be used where i am but yours is the way to go

are you having a paint shop put the paint in a spray can for you?

CigaR007 · 08-10-2011, 01:13 AM

Quote:

Originally Posted by alohaspirit

are you having a paint shop put the paint in a spray can for you?

Yup. Simply asked for colour code 6R4 (electric green mica) and the mixture was made on the spot, in 10-15 minutes.

The paint has been drying for the past few hours.

I should have a pic of the grille block on the car tomorrow.

I have yet to finish the new lower grille block though.

CigaR007 · 08-10-2011, 01:50 AM

Quote:

Originally Posted by graydonengineering

Looking great! I am thinking of doing something similar for my lower bumper. I was thinking of boxing off the slot to be pluged with plastic wrap all to make a sealed chamber and then injection expanding foam (such as Great Stuff) untill it is filled. Do you think this method would work? After that I would want to coat it and paint it. The resin coat looks like it is working well but labor intensive.

Expanding foam does wonders, but requires a fair amount of preparation in order to yield good results. Patience is key.

As per the pics, I used aluminum foil to seal and protect the surface. Plastic wrap should work too. The amount of surface preparation depends on whether or not you want the grille/bumper block to be permanently fixed/attached, or the flexibility of being able to remove it whenever you want. I chose the latter.

Albeit, I will admit that great stuff foam should be easier to deal with, since it is less messy and easily controllable. The 2-part polyurethane foam I used (PartA/PartB) requires mixing the two parts with a 1:1 ratio and you have a limited amount of time to pour the liquid before the foam starts expanding. I had a hard time in the beginning but easily managed to get the hang of it. Live and learn.

This whole fabrication of foam grille blocks has its learning curve, I will tell you that.

CigaR007 · 08-10-2011, 02:41 PM

The car needs a wash but here is the final result of the upper grille block.

A-B-A-B test will be done eventually. Need to brush up on the how-to.

jeremy96gase · 08-10-2011, 04:15 PM

Looks great especially with the matching paint.

California98Civic · 08-11-2011, 04:05 AM

Looks really good. Makes your car unique in a subtle way. I like. Do most of the lower grill too. Duct air to the radiator through the remaining opening. That would look cool too.