I'm sure this has been done many times, but I thought I would share my tutorial/adventure of making my custom grill. Enjoy!
Difficulty: 3/10
Time: Appx. 3 Hours
Cost: $35
What you'll need:- Your factory grill
- Long, skinny flat head screwdriver
- Painters tape
- Your choice of primer, paint, clear.
- Dremel Tool - if not available, see next line.
- Fine tooth saw blade from a hacksaw.
- Sandpaper - assortment of 80, 120, 220, etc. And either a sander or sanding block.
- Clothes you don't care about
- Preferably an outdoor area as it gets pretty messy
- Metal mesh-like contraption used for reinforcing screen doors found at Home Depot or Lowes - usually kept near the plexiglass, etc.
- Quick drying epoxy or Silicone/similar.
- Some sort of metal cutters or something sharp enough to cut through the fairly thick mesh material.
- Cardboard or newspaper
Directions:1) Open hood and prop open.
2) Remove grill by releasing locking tabs around the grill, one on each far end, multiple in the middle/top.
3) Take grill to your designated, well lit work area.
4) Using your painters tape, mask off the Mitsubishi emblem in the middle of the grill to avoid harming it.
5) Grab your cutting tool of choice and secure the grill firmly.
6) Begin from the "top", "top" referring to the far left side of the grill, which would be vertical towards your face. Invert when repeating for other side.
7) The plastic is very soft and cuts very easily with a hacksaw blade. Take your time.
Cut each "fin" off one at a time, creating a gap to allow full movement for removing the next fin.
Note: Leave the solid pieces on each end of the grill, that's where it gets tricky. See photo below.
9) Using your sander, sanding block or sandpaper, firmly sand down all remains from the fins around the main ring.
10) Tedious time! Remove all chrome from grill using whichever sanding method preferred, a Dremel tool works great for the whole project as it can get the detailed areas and corners well, and can also cut the fins off. The chrome is just a coating that can be sanded or peeled off. This does take some time unfortunately but it is necessary to strip the grill down to the plastic.
11) Once all chrome is removed and various grit sandpaper has been used leaving a smooth finish behind, wash the grill with warm soap and water to ensure all contaminants are removed.
12) You should now be ready to paint. This is fairly obvious process so I won't go into details, primer, paint coats, clear coat.
13) Place your grill onto your mesh backing and trace the general outside of the opening it will be filling. Remove grill and now sketch approximately 3/4" or larger around the entire outline, allowing the excess material to be folded and secured around the grill, also where it will be secured to the frame. Cut out your traced pieces and set them on your cardboard or newspaper.
14) Paint (again, not getting into details) your mesh backing prior to installing it on the grill frame in the color of your choice. Note: An alternative to this is using Plasti-Dip, also found at Home Depot or Lowes, much more resistant to rock chips, etc as it is not technically paint. about $7 per can, comes in black or white (both matte) and is removable.
15) Place your mesh pieces on the back of the grill, bend the excess material around the openings of the grill, take your time and make it snug.
16) Mix your epoxy or apply your silicone fairly heavily around the excess and edges to secure the mesh to the frame.
17) Allow proper drying time for all before re-installing on vehicle just in case something comes undone or whatnot.
18) Snap it back onto your baby and enjoy.
IF you don't want to deal with it or need help, I would be glad to help for the cost of shipping.
More pictures to come. Check back for finished product!
