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Old 12-08-2015, 05:03 PM   #1 (permalink)
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New grille block: version III

will be working till midnight's after next week and needed some extra light because of wild pigs in one certain area. these things are big and the car wouldn't stand a chance.
bought a 60w LED spot light, 6000 lumens. wired through a relay to come on using high beams only. built a bracket from an old bed frame. this is hard to drill so had to burn a hole through then clean it with a new weld.
bought a badgeless grille. needed it because the badge in the old grille didn't leave room for the light.
after removing the center section, bracket was roughed out, cut, welded, repeated same process until it worked. probably would of been quicker to measure but "measure nunce and cut twice".
layed the 1st layer of fiber mat, made sure to overlap the edges. resin doesn't stick to the plastic very well. boxed in the area around the light. used anything i had to prop/hold pieces in place until resin set. most batches were mixed hot so cure times were short.
added a clear cover to the light from a sheet i found on the side of the road. looked like a rock guard from an RV. molded grooves for it to rest in and cemented it in place.
final sheet was a heavy weave using clear resin. found it at West Marine. pricey but real good stuff.
ran a few days without the block and then with it. it really seems to contribute to FE. could all just be a fantasy but it works for me.....................

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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver


Last edited by deejaaa; 12-08-2015 at 05:27 PM..
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Old 12-08-2015, 05:05 PM   #2 (permalink)
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getto - '02 Volkswagen Jetta GLS TDI
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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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Old 12-08-2015, 05:07 PM   #3 (permalink)
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getto - '02 Volkswagen Jetta GLS TDI
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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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Old 12-08-2015, 05:09 PM   #4 (permalink)
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getto - '02 Volkswagen Jetta GLS TDI
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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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Old 12-08-2015, 05:11 PM   #5 (permalink)
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getto - '02 Volkswagen Jetta GLS TDI
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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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Old 12-08-2015, 05:15 PM   #6 (permalink)
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getto - '02 Volkswagen Jetta GLS TDI
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black plasti-dip was a temp move. didn't like it. soon removed it.

really showed how much it needed to be finished. low/high in sopts. final mat with a grinder remedied that.


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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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Old 12-08-2015, 05:17 PM   #7 (permalink)
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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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Old 12-08-2015, 05:19 PM   #8 (permalink)
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i'll get a few pics when i drive at night. pattern is spot on and better than i expected.
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Old 12-15-2015, 02:36 PM   #9 (permalink)
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That light is for low speed only, right? It might oversaturate your foreground with light, worsening your ability to see very far down the road/field.
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Old 12-20-2015, 08:54 PM   #10 (permalink)
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depends on ones definition of high speed. i drive rarely over 55-57 mph. if one is use to driving 50, then yes, it's for high speed. if used to 70 mph, then no. it's a spotlight pattern, not a flood light. it has a long range and increases long range visibility. it's only used with high beam and they work great together.
just got from a week away so haven't got any night pics yet.

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FOR SALE: 02 TDI Jetta- 5 sp: Cooper CS5 at 50 psi, UltraGauge, ventectomy, rear air shocks, mufflerectomy, LED plate light, upper fiberglass grille block, front lower pan, front fairing.
93 Chevy CrewCab 6.5 TurboDiesel, GearVendor OverDrive, 4L80 w/ TCI controls. Now DailyDriver

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