BRZ front grille mod

[BirdTRD]

Here are some tips for doing a good job.

Take your time cutting out the mustache and grill using a series of passes with the Dremel tool, first pass getting the bulk out of the way then subsequent passes to get the finished edge "perfect".

Use the right cutting bit...and a cut off wheel is not the right bit. (see pic below for correct bit)

Use 2 hands on the Dremel tool with the lower hand also braced against the material as it can and will walk on you. Practice on the scrapped mustache. I found that attacking the plastic at an angle (not 90 degrees) gives you more control. I also used several hand tools, (a rasp, file, sharp blade, sandpaper etc.) to get a clean, straight finished edge.

I used the actual bumper as my "mold" and used a heat gun and weights to get the mesh to form flush to the cut edge prior to gluing. Let the glue set up and cure with the weights still in place. JB Quik takes 6 minutes to set and 4-6 hours to cure so you have to work fast to apply it but let it fully cure before moving on.
Prep the inside surface of the bumper where the JB Quik will adhere. JB Quik doesn't "stick" well to smooth surfaces so besides cleaning the surface, gouge the crap out of it to give it some structure to grab onto. The honey combs on the mesh will serve as the structure on the grill half of things.

I initially glued the bottom edge of the mesh to the lower portion of the bumper cover but that interfered with black plastic "shelf" (for lack of a better word) that sits below the radiator/AC condenser and wouldn't let me install the lower bumper push pins as the holes didn't line up. I ended up cutting 20 mm off of the bottom of the mesh (as you see it in my pics) to allow that shelf piece (which is 20 mm thick) to slide under the mesh and allow the bottom pin holes to line up. I hope that makes sense.

[SuperTom]

I went with the 86 because I didn't like the mustache of the BRZ. I would be all over this mod if I went the brz route. Good work!

[lbrixey]

@BirdTRD thank you for the detailed write up! I will be doing this to my black Brz and will post my results!

I'm sure the JB Weld is sufficient, but I'm going to see if there is a way to mechanically fasten the grill to the bumper, for extra security.

[juliog]

This large grill mod will cause extra drag and decrease the efficiency of any heat exchangers (radiator, aftermarket oil coolers..). You're essentially making you car slower.

[JustSomeGuy]

i would like to see this on the new models with the updated look, think that would be cool but this also gives me an idea to maybe replace the frs grill with something different

[BRZen]

Originally Posted by juliog

This large grill mod will cause extra drag and decrease the efficiency of any heat exchangers (radiator, aftermarket oil coolers..). You're essentially making you car slower.

I don’t know if that’s true. My engine doesn’t seem like it’s suffering from the extra air at all. I’m about to boost my car too so the extra air for the intercooler and oil cooler should help feed the turbo and keep things cool.

[BirdTRD]

Originally Posted by juliog

This large grill mod will cause extra drag and decrease the efficiency of any heat exchangers (radiator, aftermarket oil coolers..). You're essentially making you car slower.

Not to be a d1ck but, honestly, I couldn't care less about that (even if it's true). My car is plenty fast enough and I did it for aesthetic reasons.

[pgranberg11]

Originally Posted by BirdTRD

Finally took the plunge. Lots of work but worth it. Thanks @BRZen for the inspiration!

got any pictures in better lighting? from the front and from the side with the bumper installed? the black grille is kinda blending in. I'd like to see it with some nice lighting! thanks!

nvm.. i realized i commented earlier with your other pictures..

[BRZen]

Hard to get good photos of the mesh. Here's a side-on and a more well lit photo of mine.

[juliog]

Originally Posted by BRZen

I don’t know if that’s true. My engine doesn’t seem like it’s suffering from the extra air at all. I’m about to boost my car too so the extra air for the intercooler and oil cooler should help feed the turbo and keep things cool.

It's just physics. You will be making your intercooler and oil cooler far less effective if you open up the whole grille area.

Originally Posted by BirdTRD

Not to be a d1ck but, honestly, I couldn't care less about that (even if it's true). My car is plenty fast enough and I did it for aesthetic reasons.

Up to you, it's your own car.

[Drambeenie]

Originally Posted by juliog

It's just physics. You will be making your intercooler and oil cooler far less effective if you open up the whole grille area.

Up to you, it's your own car.

Is there a performance discrepancy between the BRZ and FRS/86? I don't think there is, and the FRS/86 has the mesh grill.

[pgranberg11]

Originally Posted by juliog

It's just physics. You will be making your intercooler and oil cooler far less effective if you open up the whole grille area.

I think this is actually a great idea. As long as you can direct the air flow. I'll most likely be doing this and using foam like how ATL BRZ did with his car. The JDL intercooler goes all the way up behind the crash bar so I don't see how this would be reducing efficiency if you can properly route the airflow...

[Drambeenie]

Originally Posted by BRZen

As promised.

How did you get rid of this notch?

[BirdTRD]

Originally Posted by Drambeenie

How did you get rid of this notch?

I drew a line (red line) and cut it there, which works but makes more of a compound curve for the mesh to have to make. If I were to do it over, I would cut more material (green line) which looks like how @BRZen did it which would allow the mesh to lay in there nicer.