Mis Fit Talon partial grill block
 

Finished my grill block today using 0.125" polycarbonate sheeting.

I first used 3M weld mask to mock up and a to make a stencil.
http://i147.photobucket.com/albums/r...psdd4a1dbe.jpg

Then laid the stencil on the polycarbonate sheet and traced it out. Then I cut just the straight lines with a cut off wheel and finished the corners with a
80 grit 3M roloc 3" on.
http://i147.photobucket.com/albums/r...psdd4e881c.jpg

Then I applied on the back side of the panels "SEM Bumper Coater" This is SEM's new version that has plastic adhesion promoter built into it.
http://i147.photobucket.com/albums/r...psa015c091.jpg

This is picture removing the front side protective film off the sheeting. What you get is perfect gloss with no imperfections.
http://i147.photobucket.com/albums/r...ps15366211.jpg

This picture is both sides done and ready to install.
http://i147.photobucket.com/albums/r...psb82d9d20.jpg

Another picture of the bumper ready to go on the car.
http://i147.photobucket.com/albums/r...ps9551afe4.jpg

Taken it for a test run in 94* F out on my test loop area.
http://i147.photobucket.com/albums/r...ps8facabae.jpg
http://i147.photobucket.com/albums/r...ps704b9ef0.jpg

Before picture.
http://i147.photobucket.com/albums/r...pse334d50b.jpg

sweet!

I think your final production looks awesome, but being so shiny and brilliant kind of distracts from the rest of the car.

Your absolutely right. This winter I'm going to paint the car black. It needs a paint job badly.:o

any fe gains?

Would you kindly explain your steps in more detail for those of us pirates who do not do anything? :o

On my "Instant Mileage" data-log I showed a 1 mpg increase @ 65mph.;)

I still need to do a full tank's worth though.

1) The 3m Weld Mask is a one side sticky paper that's used for welding spark. I used it to simulate what it would look like on the bumper. Plus it doubles as a stencil. So you can stick it to the bumper and see what it looks like. Then I used 3/4" masking tape and ran it on the outline of the 3m Weld stencil so later I can match it up to drill the holes.

2) Then I laid the 3m weld mask stencil on on my poly carbonate sheet that measures 14' x 8'. I did a rough first cut with a cut off wheel and kept the corners straight at 90 degrees.

3) Then I used a 3" dia. 80 grit roloc to round the corners.

4) Then I put the poly carbonate grill covers in the 3/4" masking tape outline and pre drilled all the holes and installed them with #10 screws. Then I took them back off and pulled the back side of the protective film off to apply paint.

5) Then I painted three coat's of the SEM brand "Bumper Coater" on the back side. You can find this at your local Automotive Paint Jobber store.

6) Then I let that dry for a hour before removing the front side protective film coating. The film coating serves as a making when painting.

7) Re-installed them back onto the bumper with #10 screws.

After thinking about it you don't even need to take the bumper off.:o

Heh. PGFPro, thanks for the clarification! :)

I decided to try to figure out what I could and when I posted, you had already clarified everything! :)

Is the Weld Mask relatively cheap? Is it like one big flame-resistant sticky note? :)

Did you use polycarbonate because you have fog\sports lights?

Bacon has those, but either they burned out, or I just do not know how to use them! :o I tried to figure out to cover them. I wanted it to look good, but since I did not know if I would notice a difference, I did not want to put much effort into it.

Duct tape looked terrible! It started peeling quickly, too!

Thanks again for explaining everything!

Weld mask is not very cheap. lol I had some extra at work so I just used it, but it just like a sticky note with full adhesive not just on the top.

I used the polycarbonate because I had some left over from a race car project i did a few years ago.;)