Plastic grill block
 

Here are my instructions how to make your won grill block from ABS plastic.

You will need:
- 3mm ABS plastic
- measuring tape
- pen marker
- White paper
- Scissors
- straight liner
- sharp (hunting type) knife and skills to use it
- drill
- 6mm drill
- 50mm hole drill
- zipties

Measure the grills exact height and take off 4-5mm and place your liner on top of the ABS and put the heigth minus 4-5mm there. Use the liner to guide your knife and make 4 straigth cuts. Make the cuts to non visible side

Now the Plastic should cut half when you bend it from the point where you made the cuts. Start from the side.

take a rough estimation about the side angle of the grill and make a first cut in similar way. Now you should be able to put the grill block piece on top of grill and use that pen to sketch more precise shape. Usually its very curvy...

Take biggest pieces off with the bending method and the smaller adjustments just chi off material with the knife. Try only take max 1.5mm slices otherwise the knife wont cut and its difficult to direct it to proper way.

Put it back to place and make final adjustments and check the result. now you need to measure the width of the block and again take 4-5mm off from that value. Take the white paper and draw the shape on to the paper. If there is a straight side use that to line it perfectly on the other side. Cut the shape with scissors and put the corner to proper width and use the pen to mark the desired shape. Remember to mark it on the non visible side.

Again take the bigger parts out with bending method and smaller with chi. Now it shoudl fit in pretty nicely. Try to get gaps on the side even and there should be about 2-3mm gap on each side.

Drill the holes to places where it will push the grill block in correct form against the grill. You should drill at least two holes but I recommend three. You can concentrate the hole points with eye or the measuring tape. Put the holes where you can easily go over with regular zipties. Don`t leave there much slack otherwise the grill block will move easier.

Now you are ready to attach it with zipties according to these instructions:

http://www.youtube.com/watch?v=J8Gjk...ature=youtu.be

Voila you have saved about 5% of fuel at least in the winter.

Awesome! you should make a thread called "the aerodynamics of Zip-ties" and use it as a index of your mods!

Thanks for the post!