Thread: Fabricating Custom Car Grille (pics)

Originally Posted by parksgm

This may be a dumb question, but why go to the trouble of adding material to "make" a lip?

It seems that the existing vertical slats could be cut off flush with the horizontal surfaces, leaving a significant "lip" without the addition of any material, and the cut surface could then be sanded smooth.

Then, the desired depth of the "lip" could be achieved simply be varying the mounting depth of the wire grille: mouting the grille toward the front of the car would leave less lip, while mounting the grille further to the rear would expose more lip.

I believe that is what he is doing. But the stock lip isn't thick enough for the look he is going for. It seems that he wants to expand it to a 1/2 inch.

i usually get too much lip.

Originally Posted by GoHybrid

there is probably a local plastics supply outlet near you... but in the event you can't find one:

Many plastics can be obtained here.

The plastic sheets come in a few thicknesses, and have a haircell finish on one side. This is kind of similar to the faux leather texture sometimes stamped on vinyl for upholstery etc... If that's an issue then you can use the flip side which is smooth. I'd also look at picking up a plastic welder and some ABS welding rods. I can just about guarantee that there will be a joint that really needs gap-filling or shaping and the last thing in the world you're going to want to do is use bondo to try and smooth it out. Bondo = Problems.

It's a good idea to make your part as much out of a single material as you can. This allows it not only to bond perfectly, but it lets it expand and contract at the same rate which is critical to maintaining a painted surface or preventing cracks.

I will be looking around town today for the supply's. I'll keep you all posted! Thx as always!

Originally Posted by ArJuN

I believe that is what he is doing. But the stock lip isn't thick enough for the look he is going for. It seems that he wants to expand it to a 1/2 inch.

Ah...1/2" more THICKNESS (as in vertical dimension)...my bad.