DIY 06 grill write up

big will · 02-07-2007, 10:58 AM

Do not try this if you dont have some fabrication skills because once you cut up your factory grill a new one costs around $350.

There was more to this than I originally though. I think im going to do another one because I think I can do a better job after doing the first one. Not that im not happy with the result s of this one, I just think I can do better.

As for a write up the main thing is dont start this unless up have alot of patience.

The only tools you will need are a Dremel, philips screwdriver. Sand paper, primer, and black paint. I powdercoated the metal pieces because I was worried about paint chips and rust.

1. REMOVE THE STOCK GRILL: once your hood is open you can see 6 little push plugs that help hold the grill in place, remove these. After you remove those you can remove the grill by just pulling straight out.

YOU HAVE TO FIGHT TO GET THEM OUT

. The middle piece is easier because you can get your hand behind in and push the tabs with your fingers. Dont worry you wont break them even though it may feel like it.

2. CUTTING THE PLASTIC OUT: Now that you have the grill out you need to take it apart.
There are three parts, the painted, the one with the ugly grill in it and a back. There are a bunch of small philips screws on the back of each piece. remove them. The rest of the pieces are held together by plastic clips. Next you cut the old grill out from the middle piece. You must be carefull here or you will make more work than you need to. Leave alittle of the old grill there and just sand it down later, if you try to get to close you could end up gauging the plastic. then you need to do extra work. Now that you have everything cut out this is what you should have left.

Get the old grill all sanded off. Hopefully you dont need to do to much putty work.

3. Fitting metal into old grill: Now you need to descide how you want you grill to look. I just wanted the same design as the old one just made out of metal. Hopefully you can find a good metal fabrication place near where you live and get the stuff you need. If you have trouble PM me and I can get it real cheap and send it to you for a small fee

.

Use the back piece of the plastic grill as a guild to cut out your new screen or whatever you descided to use. Now that you have the metal cut out you put it in between the 2 unpainted plastic pieces. Cut a few spots for the metal to rest between the 2 pieces. You dont need more that 4 or 5 just enough to hold the metal in place. As you are tryin to fit the metal to the plastic notice that the plastic has a curve to it, so your metal also needs the same kind of curve.

Make sure that there is not to much hanging over the edges because you will not be able to get the new grill in the bumper. (TRUST ME ON THIS ONE)

I can not stress enough how many times you need to fit and check over and over again.

After you have the metal piece made to fit in the plastic try to put the entire grill back together to see if it all goes in the car.

after you have everything the way you want it rip it all back apart and paint your plastic and I think that $40 for powdercoating is the way to go. You dont want a paint chip rusting, then you get rust water on you paint and that cant be good.

The last thing is the STI emblem, You need 2 #10 speed nuts to hold it on.

srt42sti · 02-07-2007, 01:11 PM

great job! nice write up too.

johnson81 · 02-07-2007, 01:58 PM

Thanks for the wite up and pics. Looks good! I think I'm gonna give this a shot.

La Mer · 02-07-2007, 02:01 PM

great write-up.

any pics further away to show the entire 'look' of the grill installed?

big will · 02-07-2007, 02:01 PM

if you have any questions you know where to find me

big will · 03-07-2007, 04:44 PM

bump for guys looking for the write up

Pennywise · 03-25-2007, 01:25 PM

Thank you big will, great write up

Ikon · 03-25-2007, 02:21 PM

nice job

06SpecC · 03-25-2007, 08:18 PM

Nice write-up! I think i'm going to try this since its wayyy cheaper than paying $500+ for the JDM Spec C mesh grilles, I just need to find mesh that matches the Spec C ones...

Al from jerz · 03-25-2007, 08:27 PM

Thanks for this, nice work. I think it looks real good

02-07-2007, 10:58 AM	#1
big will STI Driver Car: 06 AW STI on gold Fav Mod: CBRD tune Location: Lancaster PA Posts: 299 Join Date: Apr 2006 Trader Rating: (0)	DIY 06 grill write up Do not try this if you dont have some fabrication skills because once you cut up your factory grill a new one costs around $350. There was more to this than I originally though. I think im going to do another one because I think I can do a better job after doing the first one. Not that im not happy with the result s of this one, I just think I can do better. As for a write up the main thing is dont start this unless up have alot of patience. The only tools you will need are a Dremel, philips screwdriver. Sand paper, primer, and black paint. I powdercoated the metal pieces because I was worried about paint chips and rust. 1. REMOVE THE STOCK GRILL: once your hood is open you can see 6 little push plugs that help hold the grill in place, remove these. After you remove those you can remove the grill by just pulling straight out. YOU HAVE TO FIGHT TO GET THEM OUT. The middle piece is easier because you can get your hand behind in and push the tabs with your fingers. Dont worry you wont break them even though it may feel like it. 2. CUTTING THE PLASTIC OUT: Now that you have the grill out you need to take it apart. There are three parts, the painted, the one with the ugly grill in it and a back. There are a bunch of small philips screws on the back of each piece. remove them. The rest of the pieces are held together by plastic clips. Next you cut the old grill out from the middle piece. You must be carefull here or you will make more work than you need to. Leave alittle of the old grill there and just sand it down later, if you try to get to close you could end up gauging the plastic. then you need to do extra work. Now that you have everything cut out this is what you should have left. Get the old grill all sanded off. Hopefully you dont need to do to much putty work. 3. Fitting metal into old grill: Now you need to descide how you want you grill to look. I just wanted the same design as the old one just made out of metal. Hopefully you can find a good metal fabrication place near where you live and get the stuff you need. If you have trouble PM me and I can get it real cheap and send it to you for a small fee. Use the back piece of the plastic grill as a guild to cut out your new screen or whatever you descided to use. Now that you have the metal cut out you put it in between the 2 unpainted plastic pieces. Cut a few spots for the metal to rest between the 2 pieces. You dont need more that 4 or 5 just enough to hold the metal in place. As you are tryin to fit the metal to the plastic notice that the plastic has a curve to it, so your metal also needs the same kind of curve. Make sure that there is not to much hanging over the edges because you will not be able to get the new grill in the bumper. (TRUST ME ON THIS ONE) I can not stress enough how many times you need to fit and check over and over again. After you have the metal piece made to fit in the plastic try to put the entire grill back together to see if it all goes in the car. after you have everything the way you want it rip it all back apart and paint your plastic and I think that $40 for powdercoating is the way to go. You dont want a paint chip rusting, then you get rust water on you paint and that cant be good. The last thing is the STI emblem, You need 2 #10 speed nuts to hold it on. This ad is not endorsed by this member. Please register or login to hide this ad.

02-07-2007, 01:11 PM	#2
srt42sti Professional STI Driver Car: 06 STi CGM Fav Mod: what you cant see :-D Posts: 418 Join Date: Jul 2006 Trader Rating: (3)	great job! nice write up too.

02-07-2007, 01:58 PM	#3
johnson81 STI Driver Car: 06 STi Fav Mod: Espelir JGT500 cat-back Location: Kent, WA Posts: 221 Join Date: Nov 2005 Trader Rating: (2)	Thanks for the wite up and pics. Looks good! I think I'm gonna give this a shot.

02-07-2007, 02:01 PM	#4
La Mer NIИja Car: 2006 STI (SGM) Location: US - Southern California Posts: 38,192 Join Date: Jan 2006 Trader Rating: (5)	great write-up. any pics further away to show the entire 'look' of the grill installed?

03-07-2007, 04:44 PM	#6
big will STI Driver Car: 06 AW STI on gold Fav Mod: CBRD tune Location: Lancaster PA Posts: 299 Join Date: Apr 2006 Trader Rating: (0)	bump for guys looking for the write up

03-25-2007, 01:25 PM	#7
Pennywise Professional STI Racer Car: 06 black sti Fav Mod: remote start Location: Boostin, MA Posts: 659 Join Date: Feb 2006 Trader Rating: (0)	Thank you big will, great write up

03-25-2007, 02:21 PM	#8
Ikon Welcome to The Board Car: 06 WRB STI Fav Mod: Advan RS Location: Starbucks, WA Posts: 5,628 Join Date: Mar 2006 Trader Rating: (10)	nice job

03-25-2007, 08:18 PM	#9
06SpecC Professional STI Racer Car: 06 STi Spec C Fav Mod: The STi experience Location: Cape Coral, FL Posts: 654 Join Date: Oct 2006 Trader Rating: (6)	Nice write-up! I think i'm going to try this since its wayyy cheaper than paying $500+ for the JDM Spec C mesh grilles, I just need to find mesh that matches the Spec C ones...

03-25-2007, 08:27 PM	#10
Al from jerz Junior STI Driver Car: 06 Subaru WRX STi Posts: 112 Join Date: Aug 2005 Trader Rating: (0)	Thanks for this, nice work. I think it looks real good This ad is not endorsed by this member. Please register or login to hide this ad.