Project pretty prius grill block

[Daox]

I thought about fiberglassing the whole thing, and that might have worked had I done it right off the bat. However, its now mashed and disformed from holding it while sanding. So, that is no longer an option for me. The only thing you'd have to be careful with if you did do it that way would be fitment issues. Since the foam expands between the grill's slats, you would need to sand that foam down before putting fiberglass over the top otherwise it might not fit back on well. I'd think it would also probably scratch the paint on the grill slats if you are worried about that.

[Quasimoto]

Another thing a person could do is to lay the glass mat right on the aluminum foil. Let it set up; then fill it with foam to the thickness you need; sand down the foam then glass over it.

[ncc74656m]

Excellent idea, Quasimoto!

[Daox]

Yes, that would have worked much better than what I did. New ideas for next time!

[ncc74656m]

Originally Posted by Daox

Yes, that would have worked much better than what I did. New ideas for next time!

Or for me! :P

I love my Corolla (now), but I really would like to do something for a little bit better mileage...

[CigaR007]

In order to avoid the foam to be crushed while sanding, I kept it on the upper grille for support (which is removable on my car), especially when I applied the epoxy resin coatings. That way, the foam maintains its shape and it is not damaged in any way. I did not use fibreglass though. Seems to be quite solid without it, even after a few months of usage. We will see how it handles the winter.

[talonts]

I say don't worry about the back. Carve it out, glass in some rare earth magnets, and put some brackets in the nose with matching magnets. Easy removal, but will stay put. Well, easy removal if you don't go too large on the magnets ;-)

You can put foam tape on the back to protect the grille if needed.

[Daox]

Yeah, I was thinking some foam tape would work nice for protecting the car's paint once it was done.

Magnets would be a cool way to attach it too.

[Chris D.]

finally, some areo mods with a clean look to them..

And it didn't cost a while lot to do..

i want to mod my Corolla, but retain some sort of clean look..
I'll be doing something like this as soon as I find a doner grill..

[F8L]

That is going to look a lot nicer than our typical grille block method.

Here is the method most of use Prius owners run: