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Discussion Starter #1 (Edited)
[FONT=&quot]HD GRILL GUARD MOD: UPPER GRILL[/FONT]

THIS PROJECT (DONE MAR 4-5, 2010) IS DETAILED OUT FOR -ONLY- 2009 AND 2010 MODEL’S GRILLS. THERE IS A BIG DIFFERENCE IN TERMS OF THE UPPER GRILL OPENINGS AND I STARTED THIS AS A LOWER GRILL MOD. A SEPARATE THREAD IS SET ASIDE (SORRY MODS!) TO DETAIL THE “LOWER GRILL GUARD MOD” WHICH INCLUDES A DETAILED ACCOUNT OF THE BUMPER REMOVAL..

What follows is my 2009-10 Upper Grill Guard Mod using the metal Home Depot gutter screen without and with paint… For those of you that are handy, you’ll appreciate the detail… I did look at the other threads on this mod and did mine this way so that those of us who are not mechanically inclined (READ DISCLAIMER) have a resource to figure this stuff out… To those folks who are like me, by all means, follow this account and my bumbling hands to the end…! I’ve pared this down from 150+ photos to what you have before you…

DISCLAIMER: I AM NOT MECHANICALLY INCLINED BY ANY MEANS AND I TOOK THESE PICTURES IN CASE I FORGOT A STEP OR PROCEDURE ALONG THE WAY. PLEASE READ THE ENTIRE THREAD FROM BEGINNING TO END AND IF YOU CANNOT SAFELY HANDLE 30-40 LBS, GET ANOTHER SET OF HANDS TO HELP YOU. I DID THIS PROJECT AFTER 7 MONTHS OF OWNERSHIP BECAUSE IT TOOK ME THAT LONG TO GATHER UP ENOUGH COURAGE TO DO THIS ON MY OWN. I’M A BIG GUY AND DID THIS BY MYSELF BUT BECAUSE I ADMIT TO BEING AN IDIOT AT TIMES, I TOOK THE PICS TO COVER MY BUTT. THE PROJECT TOOK 2-AFTERNOONS TO COMPLETE (BECAUSE OF PAINT DRYING TIMES) AND THE LAST PHOTO WAS TAKEN ON A SUNNY DAY TO SHOW THE FULL RESULTS OF MY GOOD ‘OL LUNCH BOX. NOW WOULD BE A GOOD TIME TO CLEAN OUT THE FINS OF THE CONDENSER/RADIATOR FRONTS NOW THAT THE BUMPER IS OFF. DO THIS PROJECT AT YOUR OWN RISK! WORK SAFELY AND HAPPY MODDING!

List of tools used:

  • Screwdriver-flat head: to pop-out clips
  • Screwdriver-Philips: screw removal
  • 10mm socket & wrench: stepped bolt removal
  • Black marker: to mark my template
  • Leather gloves: to prevent cuts on my hands
  • Tin snips: to remove excess metal
  • Wire cutters: to trim zip ties
  • Blanket-to lay the bumper on

Home Depot / Wal-Mart purchases:

  • HD-Gutter Guard $2.16 each (I got 2 for Upper and Lower Grill Mods)
  • WM-Spray Paint: Rust-Oleum Automobile Primer (Dark Gray) $3.97
  • WM-Spray Paint: Rust-Oleum Flat Protective Enamel (Black) $3.97
  • WM-Leviton 4-Inch Cable Ties (Black/100-count) less than $2 (had these for a long time/need 10-for this project)
  • Total: $14.26 + 9.75% tax = $15.65

[FONT=&quot]UPPER GRILL GUARD MOD:[/FONT][FONT=&quot] (27-PHOTOS)[/FONT]

Step One: BUMPER REMOVAL (REFER TO PAGE 3 ON THE PDF FILE FROM H-AND-A)

Follow this LINK or follow here:

http://www.handa-accessories.com/element/10fogs.pdf

On page 3 of the D-I-Y Fog Lights Installation Instructions (from our good friends at H and A), you’ll see the diagram of where all the clips, bolts and screws are to remove the bumper. Or, you can go to my HD Lower Grill Mod thread HERE.



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Step TWO: (OPTIONAL)

Remove the upper grill assembly from the bumper. Clips are marked with arrows and I only used the flat-head screwdriver to pop the clips off. If you decide to skip this, go to Step THREE:



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PHOTO: Upper grill removed from bumper.



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A better view.



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Step THREE:

Time to draw a template. Use a marker and tin snips. I planned on bending down the grill guard along the sides of the grill to eliminate the need to have to drill holes on the sides to mount the screen. SPECIAL NOTE: EXTEND THE TEMPLATE BORDER SIDES BY ONE-INCH!!!



CONTINUED...
 

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Discussion Starter #2
HD Grill Upper Guard Mod 2009-10 Edition (WARNING: Picture HEAVY!!!)

Step FOUR: BOTTOM REMOVAL-WEAR GLOVES!!!

Cut. Be VERY CAREFUL!!! The edges of the screen are SHARP!!! I wore thick leather gloves (not in picture) while cutting (which I removed to take a picture). I pushed the excess metal down so that it would not get in the way of the rest of the screen I had to remove. Work safely, work slowly…!



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Steps FIVE thru SEVEN: SIDE REMOVAL-TEMPLATE (#5), CUTTING (#6), AND SHAPING (#7)



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#6. Cut and bend. WARNING: Use thick leather gloves to bend the metal side down. THE METAL EDGE IS SHARP!!!



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#7. Bend the other side. WARNING: Use thick leather gloves to bend the metal side down. THE METAL EDGE IS SHARP!!!



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RESULT: The Grill Guard is totally shaped and ready for mounting.



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PHOTO: Test fit. If you like this look, skip down to Step NINE:



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Step EIGHT: (OPTIONAL: CUSTOM FITTING & PAINTING)

CUSTOM FITTING: (TEMPLATES)



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Use the side of a pencil to make a copy of the impression of the rim.



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Note: Remember, the letter-size sheet of paper will NOT reach left to right so keep that in mind when doing this! I use the same marker to finalize the template / image. Since there is a slight curve to the gutter screen, I’m using a paper template to do make this easier.




CONTINUED...
 

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Discussion Starter #3
HD Grill Upper Guard Mod 2009-10 Edition (WARNING: Picture HEAVY!!!)

Before cutting, measure again. I placed the paper template to give me an idea of what I have to cut. Then I transferred the pattern onto the metal screen.



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Now cut.



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The start of the custom fitting.



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Mark the curve. Notice the cut on my left thumb? I didn’t wear gloves!!! WEAR GLOVES when dealing with this stuff!!!



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Carefully, CAREFULLY trim off the excess.



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All trimmed up!



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Time for paint! Refer to the list above to see the spray paint (cost & color) that I used to do this project or look at the photos! Allow to dry for 15-30 minutes. Flip over and do the other side. Wait 15-30 minutes. Repeat painting both sides.



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Step NINE: CABLE/”ZIP” TIE TIME!


Time to attach the screen to the grill with zip ties. I used EIGHT total so that there was plenty of support for all parts of the screen. Use the wire cutters to trip the excess zip tie “tabs”. Leave ¼ to ½ inch tab sticking out. Relax! No one will see it! The clipped side will be on the INSIDE!



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Time to trim.



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Time to put it all back together.




CONTINUED...
 

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Discussion Starter #4 (Edited)
HD Grill Upper Guard Mod 2009-10 Edition (WARNING: Picture HEAVY!!!)

WARNING: IT’S REALLY A “HEADS-UP”. WHEN RE-MOUNTING THE BUMPER, MAKE SURE YOU PUSH UP THE BOTTOM OF THE PLASTIC SHROUD -UP-. NOTE: THIS IS WHERE ANOTHER SET OF HANDS COMES IN REAL HANDY. OR DO WHAT I DID-USE A PROP (SMALL BOX). OTHERWISE, IT’LL LOOK LIKE THIS BEFORE THE CLIPS, BOLTS, AND SCREWS ARE PUT BACK IN. DON’T RUSH LIKE I DID! D’OH!!! :homer: (a la Homer Simpson!)



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FINAL RESULT:



Thanks for stopping by…! Let me see the results of your mods and post your pictures here…!!! LBD
 

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Discussion Starter #5
Thanks RamblerDan...!

Just wanted to thank you for all your work and understanding on this particular thread...!

LBD
 

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good to know the upper grill disconnects from the rest of the bumper. I think its ugly, and I've been thinking if I do anything to alter the appearance of my E, it'll be scrapping that.
 

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Discussion Starter #8
Tromo...

Sorry for getting back to you so late... Don't forget to post up your results when you make your mod...!

Good luck...

LBD
 

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hey lbd....don't know if my computer is screwing up, but i don't see pics of the end result....i'd like to see it :)
 

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Discussion Starter #10
Touche' buddy...!

LOL!!!

LBD
 

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Grill Mod - "Dropped in from top".

After reading several threads, and seeing some great photos and instructions, I did my grill mod a few days ago. I made a template for the upper, and slipped it in from above, after removing only the plastic cover on top of the core support. I put the tie wraps into the screen before slipping it in, so that the tie wrap large ends would be behind the grill. For the lower I slipped the screen down past the upper mod, pulling the grill out a bit to clear, and positioned it from the outside, with the tie wraps pre-loaded also. (Easier to type than the process) I then removed the licence plate bracket and lower clips for the bumper cover. There is not much room to work, but the cover can be pulled back to access the other end of the tie wraps. Be sure to put the licence plate bracket back on before tightning the tie wraps on the lower screen. I left the aluminum screen as is, rather than painting them black. Sort of makes the front "pop" with contrast IMO.
 

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Discussion Starter #12
Nice job on yours Notanku...! You plan on doing something with the foggy holes...? Keep on moddin' buddy...!

LBD
 
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