C5 A6 front lower grille mod
04-07-2008, 09:31 PM
#1
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Location: Calgary
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C5 A6 front lower grille mod
Hi guys, just finished phase 1 of modding my 3 front lower grilles. I used the stock inserts for the base of this mod. Let me know what you think. I still need to add 2 or 3 good coats of paint, i think the untouched aluminum is a bit much. I will tackle the upper when the lowers are finished 100%. Very simple mod, if there is enough interest I will post a step by step.
Last edited by nothing77; 04-07-2008 at 10:00 PM.
04-07-2008, 10:05 PM
#2
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Join Date: Aug 2007
Location: Etobicoke
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Re: C5 A6 front lower grille mod
I really like it, let us know the progress. If you have time to do a step by step i'd like to see it.
Also, i'd take it one level further by doing something with the stock grille.
Also, i'd take it one level further by doing something with the stock grille.
04-07-2008, 10:21 PM
#3
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Re: C5 A6 front lower grille mod
Absolutely I am planning to perform a similar mod on the stock upper grille as well. I will put a step by step together. And like I said this mod still requires the final painting to black, not so much bling on the grille.
04-07-2008, 10:46 PM
#4
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Re: C5 A6 front lower grille mod
Step by Step
Tools- dremmel
jigsaw
offset tin snips
sidecutters
linesman pliers
Materials- expanded aluminum (good quality from a custom metal shop)
16 ga wire
Step 1: Remove all three of your lower front grilles, the fog light grilles pull out easiest if yuou grab them nearer to the center grille and pull. Center grille is a bit stiffer, you may need to drop the front bumper to pull it out
Step 2: Take your 3 inserts and get ready to cut, for this process I tried various tools and techniques. In the end I found a combination of sidecutters and jigsaw worked the best.
Step 3: What to cut? On the center grill you will find that there are vertical support brackets behind the horizontal grilles. these must stay in tact, as they hold the mounting tabs. I cut out all the horizontal grilles, trimmed back vertical supports so they were all even.
Step 4: Once the cutting is done use the dremmel with drum sander attachments to clean up the raw edges of the cut ABS plastic
Step 5: You should now have the outer trim piece with the vertical supports inset slightly, from here you take your expanded aluminum and cut it to approximate size ( slightly larger than required). take your time lining the metal up, try to create an even look on all sides.
Step 6: mark your metal and cut to fit inside insert( again slightly large), this process is tedious and requires patience. You keep fitting and re-fitting while constanting timming to get the perfect fit.
Step 7: Once you are happy with the fit, take the 16 ga wire. Wire the new grille insert onto the vertical supports. If you cut your metal correctly, you will be able to hide the wire on the underside of the metal expansions(barely visible up real close) Use the linesman pliers to twist the wire until it is tight , your grille insert shouldn't budge
the fog lights are much the same process, I left the part which directs the fog light beam intact to help keep the light shining in the right direction. Fog light gilles only have 2 vertical supports, but you get the idea.
All three of these grilles should fit with ease back into their original location, using their stock mounting clips. I plan on finishing my grilles with 3 coats of high quality black paint.
good luck, have fun
Tools- dremmel
jigsaw
offset tin snips
sidecutters
linesman pliers
Materials- expanded aluminum (good quality from a custom metal shop)
16 ga wire
Step 1: Remove all three of your lower front grilles, the fog light grilles pull out easiest if yuou grab them nearer to the center grille and pull. Center grille is a bit stiffer, you may need to drop the front bumper to pull it out
Step 2: Take your 3 inserts and get ready to cut, for this process I tried various tools and techniques. In the end I found a combination of sidecutters and jigsaw worked the best.
Step 3: What to cut? On the center grill you will find that there are vertical support brackets behind the horizontal grilles. these must stay in tact, as they hold the mounting tabs. I cut out all the horizontal grilles, trimmed back vertical supports so they were all even.
Step 4: Once the cutting is done use the dremmel with drum sander attachments to clean up the raw edges of the cut ABS plastic
Step 5: You should now have the outer trim piece with the vertical supports inset slightly, from here you take your expanded aluminum and cut it to approximate size ( slightly larger than required). take your time lining the metal up, try to create an even look on all sides.
Step 6: mark your metal and cut to fit inside insert( again slightly large), this process is tedious and requires patience. You keep fitting and re-fitting while constanting timming to get the perfect fit.
Step 7: Once you are happy with the fit, take the 16 ga wire. Wire the new grille insert onto the vertical supports. If you cut your metal correctly, you will be able to hide the wire on the underside of the metal expansions(barely visible up real close) Use the linesman pliers to twist the wire until it is tight , your grille insert shouldn't budge
the fog lights are much the same process, I left the part which directs the fog light beam intact to help keep the light shining in the right direction. Fog light gilles only have 2 vertical supports, but you get the idea.
All three of these grilles should fit with ease back into their original location, using their stock mounting clips. I plan on finishing my grilles with 3 coats of high quality black paint.
good luck, have fun
the secret to painting my friend
