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Mesh Front Grille

Originally posted on Briskoda by member Bowders1
http://briskoda.net/forums/topic/157267-front-bonnet-grille-mod/

Printable PDF version here

Start by removing the front grille by undoing the 4 top torx screws
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Then remove the 4 outer torx screws (2 on each side)

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Unfortunately I did not take pics of the Grille in one piece and I already cut the vented part from the main black plastic grille but I can explain what you do to split the section apart

The Grille comes in 3 sections (imagine the vented part is still attached to the main black section in the pics below)
The 3 sections are:
The Main base (Black Plastic part)
The Colour coded section that fits to the main grille
The Chrome section that fits to the colour coded section

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This is the front part of the grille (chrome section). You need to simply unclip the sections apart using a suitable flat screw driver.
Starting with the chrome plastic section cut off the clips on the surround and smooth them so they are flush with the rest of the back. Pic shows the back of the chrome section smoothed.

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Working with the chrome section, make a card template to use to cut the mesh to correct size. This way to can check that you have the correct size before you waste the mesh by cutting too short. You need to make the template have a 5mm overlap to fold it down the side of the chrome section.

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Cut mesh ready to check size

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Now you need to carefully fit mesh to the chrome section and bend the overlap around the edge of the section. Take time on this and be sure it is as tight to the chrome section as possible as this is going to make the difference when sealed. Spend time around the koda centre badge area making sure that the mesh is flat and formed into the rear of the badge.

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When you are happy then you can seal it in place.
I used black tiger seal mastic, which most paint shops use for fitting spoilers etc great adhesion and flexibility. Any decent adhesive sealant will do really

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Pic of the badge area (note pic shows the rest of the section together but you get the gist)

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Next you need to fix that chrome section back to the colour coded section. As the tabs have been removed(to allow the mesh to sit close) you need to use tiger seal again, Run a bead around the inside or the coloured section where the chrome part will be sitting. I ran a thick bead approx 5mm down from the top edge of the coloured section, then sat the chrome section into it. I placed something over the grille to make sure is pressed in and left it over night

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Then whilst that was drying I started on the black main grille section.
Start by using an angle grinder or dremel to cut out the grille slats. You need to cut lower then the slats as the mesh section needs to have enough space to sit it this main section with the mesh part not being obstructed. You will see when you fit the two together.
Take time to slowly cut away the waste.

Pic of the first cut I made showing the slatted part removed.

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Final pic of the edge rubbed down and smoothed

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Base section ready to be connected to the mesh section

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To fit together they just need to be re-clipped.

Pic shows the complete item clipped together from behind, you can see how close the black base and coloured section are by the black sealant just being visible that sealed the initial mesh to the chrome section

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Finished article

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