BDII Posted November 2, 2007 Share Posted November 2, 2007 I couldn't bring myself to pay $250 for the RBS, or $150 for an ebay knock off that never fits, so I decided to make my own. I've never done anything like this before so it was def a learning experience This is how I did it.... THINGS YOU WILL NEED 1. Dremel or the like and a accessory kit http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01551.jpg 2. Sand Paper, 3 levels, light, medium and heavy 3. Screw Driver 4. Super glue 5. Eye protection 6. spray paint (primer, metallic color and clear coat) 7. Bondo kit 8 metal body patch 9. Gutter, honey comb mesh (6" x 2') 10. zip ties 11. Paper clips STEP 1 Use the dremel to remove the inside: http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01553.jpg This is the hardest part.... have patience and do this in a well ventilated area. Step 2 Use the grinder tool to smooth all of the edges, be careful not to grind to deep or you will have to fill in the holes. http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01555.jpg http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01556.jpg http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01554.jpg Once your satisfied with your sanding and all of the edges are smooth. Take a shower. no really... put the grill under running water to remove all of the dust. http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01557.jpg Step 3 BONDO TIME!!!! make sure you do this in a well ventilated area or you will get sick or high or a combination of the 2 Take the metal patch and place it over the four holes and cut to size: http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01558.jpg http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01559.jpg http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01560.jpg next, paper clip them on, this will hold them in place. http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01565.jpg Now this is the tough part..... BONDO over the paper clips.... you have to wait no more than 5 minutes then pull the paper-clips off before the bondo sets.... if you don't you will have to saw them out. The BONDO should hold the mesh and break apart to let the clips out. http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01561.jpg Step 4 Once the bondo dries, sand it down using the dremel with this bit http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01569.jpg be careful not to go to deep, use the sand paper if needed. it should end up looking like this http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01572.jpg Step 5. Once all the bondo is done, drill holes on the top inside for the zip ties to attach the mesh like this: http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01568.jpg Step 6 Sand again with high grit, them medium grit, then low grit Wipe down the grill with a moist cloth to remove all of the dust. Step 7 Apply 3 thin coats of primer, ensure the entire grill is covered and you can't see any chrome or black plastic, do the same to the mesh, let dry http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01575.jpg Next, apply 3 good coats of the color of your choice, let dry Next, apply 3 good coats of clear coat, let dry. Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
BDII Posted November 2, 2007 Author Share Posted November 2, 2007 Step 8 It's mesh time!! Place the mesh on the backside of the grill and bend to form, trim the excess. http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01580.jpg next, attach the zip ties to the mess through the holes you made, ensuring a snug fit! http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01579.jpg I didn't use anything on the bottom, you can super glue it if you like, but this is tedious.... and smelly. This is what is ended up looking like: Before http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01582.jpg After: http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01584.jpg Before and after http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01581.jpg Excuse the finger prints.. they wipe off http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01585.jpg Try not to stab yourself with the screw driver whilst removing pop its http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01586.jpg Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
c-lo Posted November 2, 2007 Share Posted November 2, 2007 good job. when you going to start taking orders? My old grill needs some work. it was modified by Subastyle; looks similiar to yours. 258k miles - Stock engine/minor suspension upgrades/original shocks/rear struts replaced at 222k/4 passenger side wheel bearings/3 clutches/1 radiator/3 turbos Link to comment Share on other sites More sharing options...
BDII Posted November 2, 2007 Author Share Posted November 2, 2007 I'm in the process of getting vendor status, waiting on Tide to get back to me. If and when I do..... $100 shipped for the grill or $80 plus your stock. I won't do Red... to hard to color match. I can also attach subaru/Sti/L7 or any other badge at no additional cost if you proved the emblem Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
RobE Posted November 2, 2007 Share Posted November 2, 2007 http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01568.jpg The money shot. http://newenglandsubarus.com/ Link to comment Share on other sites More sharing options...
BDII Posted November 3, 2007 Author Share Posted November 3, 2007 This is actually a lot easier to do than I thought. I'm on my second already, and starting a third tomorrow. Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
PhilT Posted November 3, 2007 Share Posted November 3, 2007 http://i44.photobucket.com/albums/f43/Bu11dogg2/DSC01586.jpg Didn't your mom tell you if you did it too much it would make it bleed Double Award Winning Legacy GT Wagon Link to comment Share on other sites More sharing options...
BDII Posted November 3, 2007 Author Share Posted November 3, 2007 I literally pulled the screw driver out of my hand Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
-TT- Posted November 3, 2007 Share Posted November 3, 2007 nice write-up! Link to comment Share on other sites More sharing options...
starhm Posted November 3, 2007 Share Posted November 3, 2007 Nice job!!! Link to comment Share on other sites More sharing options...
rawfish Posted November 3, 2007 Share Posted November 3, 2007 nice write up!!!!! After awhile I notice my mesh started to show rock chips(ghetto) So I had it powdercoated for $10 diffinitely worth it. Link to comment Share on other sites More sharing options...
Underdog Posted November 3, 2007 Share Posted November 3, 2007 +1 on your workmanship -1 on the look... Put the logo in the center or something! The Crimson Dynamo Link to comment Share on other sites More sharing options...
J.R. Posted November 3, 2007 Share Posted November 3, 2007 Once you get that vendor status, let me know where I can send mine. Too lazy to do it myself, and am unhappy with the way my JDM grill fits. Link to comment Share on other sites More sharing options...
BDII Posted November 3, 2007 Author Share Posted November 3, 2007 +1 on your workmanship -1 on the look... Put the logo in the center or something! The logo is going on once the rain stops Once you get that vendor status, let me know where I can send mine. Too lazy to do it myself, and am unhappy with the way my JDM grill fits. Is sure will Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
bosco Posted November 4, 2007 Share Posted November 4, 2007 come on guys he put a lot of work into this and i would like to see the thread stay i feel it will help others who want to try this also if he gets vendor status and sells some of them thats fine to. thanks bosco Stay Stock Stay Happy Link to comment Share on other sites More sharing options...
BDII Posted November 4, 2007 Author Share Posted November 4, 2007 bosco Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
Canon20D Posted November 4, 2007 Share Posted November 4, 2007 looks awesome - for the price id have you do mine! Link to comment Share on other sites More sharing options...
BDII Posted November 5, 2007 Author Share Posted November 5, 2007 I just purchased vendor status. Who wants one? http://legacygt.com/forums/showthread.php?p=1484006#post1484006 Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
smitty Posted November 6, 2007 Share Posted November 6, 2007 great write up Link to comment Share on other sites More sharing options...
BDII Posted November 7, 2007 Author Share Posted November 7, 2007 thank you Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
SMH90 Posted January 29, 2008 Share Posted January 29, 2008 Nice work, but i had a different way of approaching it... i didnt want to spend the money on buying a factory one so i customized mine. Instead of bondoing the channels, im using a dremel to cut an even amount out all the way around the edges. it will have a shorter base, but less hassle(for me). then, as you did, i have gutter guard for the backing and painted it flat black. To finish, im going to put "SUBY" or "LEGACY" across the bottom right corner with lettering that i took from the trunk. I'll post pictures as soon as i take them!! Link to comment Share on other sites More sharing options...
frkkevin Posted January 29, 2008 Share Posted January 29, 2008 actually trimming the grill down is a good idea i filled in the bottom gap with a piece of plastic i cut from a plastic paint pallet i picked up from hobby lobby.. it was the same thickness as the grill.. so i glued it in and barely had to use any bondo to fill where it was.. no worries about cracks later on 512whp/465ftlb 2005 5EAT Legacy (Build Log) Videos - - Link to comment Share on other sites More sharing options...
BDII Posted January 29, 2008 Author Share Posted January 29, 2008 Pics? Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
SMH90 Posted February 5, 2008 Share Posted February 5, 2008 http://a118.ac-images.myspacecdn.com/images01/3/l_163e81eff9ce08586d4e4f55584c50ad.jpg Before http://a878.ac-images.myspacecdn.com/images01/58/l_5c836704b33fb29ddc9fe21c3a0c282d.jpg After. (cell pic) All together it took a couple hours.. not tooo hard. u need gutter guard, a dremel and paint! Link to comment Share on other sites More sharing options...
BDII Posted February 5, 2008 Author Share Posted February 5, 2008 I'm not able to see the last pic Need forum help? Private Message legGTLT Link to comment Share on other sites More sharing options...
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