Functional Mid-Grill

[k-huevo]

Originally Posted by mini_racer

K, it looks like you originally left the 2 holes on the outside, then you must have come back for more removal...but for installation alignment purposes it might make sense to mark the carrier position before you remove it.

I made a mistake on one end and had to do the same to the other for the sake of symmetry.

There is a bolt with a nylon sleeve that fills an alignment hole, so the bumper will go on in the same location as removed.

[mini_racer]

Ok, thanks on the easy alignment info, and I hear ya...............it's got to be even!

[Alan]

See attached...

Originally Posted by k-huevo

Please share a photo with us Alan. The standard bumper cover allows a straighter path through the openings without the slat in the way, and it looks down right aggressive.

[mini_racer]

OK, my aero grill just came in today and the bonnet portion is installed. I really like it better, yeah! Tomorrow the bumper cover and carrier come off then it will be time for a little jigsaw work to clear the air path through that upper bumper grill. I'll post a few pics, but it will look very similar to the ones K already posted.

[mini_racer]

Oh man, what a PIA it is to fit the Aero grill to a standard S bumper. This is the longest and most involved 'small' job I have ever done.

The bumper cover and the mid-grill are all trimmed, just need to finish final fitment, and then add a little glue on the backside for insurance, just like OEM.

The bumper air flow trimming is today. I expect this will go more quickly than the job thus far.

Oh, and if/when you do this, definitely use a jigsaw, do not use a 'saws-all' type of saw you see used in some of the on-line instructions, there is just not enough control with that type of saw.

[mini_racer]

Originally Posted by k-huevo

Hey K,
What is this solid piece in the middle of your bumper cover behind/under the mid-grill? I don't have a structure like that on my bumper cover. With the slat removed, my opening just extends all the way left to right, as shown in Alan's pic.

Also, not sure how visible the carrier is behind the mid-grill, but have you considered painting the edges of the Al carrier black?

[k-huevo]

That is a feature on the aero bumper cover; the aero is made of thinner and more pliable plastic than the fairly rigid ABS of the standard bumper cover. It needs more support, so I left the mid strip intact. As I recall the standard bumper cover has a one-inch wide clip at that location. I recommend not cutting the center portion on the bumper either. There must be support there or it will bend downwards easily. I know someone who removed the entire holed section to place various electronic controllers in the gap and it later bent badly after unplanned pressure was put upon the top of it. This is also why I suggest removing only what is necessary to provide airflow to the radiator from directly in front; leaving three holes on each end will still allow a direct path and will give more support to the bumper shell. Note the radiator and AC heat exchanger are offset to one side and its width is less than the mid-grill trim width.

Be sure to have extra blades on hand before starting, I used up five blades in the bumper cutting.

[mini_racer]

1. Ok, I didn't know the aero cover was different in that manner.
2. For my standard cover, I debated, and eventually cut out that one inch wide clip in the middle. If I had it to do again, I would leave it in. Regardless, the aero mid-grill fits snuggly with the tabs in-place and after installation, with some glue on the backside, will serve as additional structure for the bumper cover. The mid-grill itself is very rigid. I saw somewhere, NAM maybe, where one installation used zip-ties on the backside of the tabs to lock them in-place. That's an idea that deserves a little exploration.
3. For the Al carrier, I agree completely with cutting the minimal amount required to maximize flow. However, it seems like leaving 2 holes on each end is only what is required. Leaving 3 holes would limit some flow.
4. I think I will have to paint black the parts of the carrier that will show thru the mid-grill. This includes: the section thru the middle with the two holes, the bottom lip of the opening, and the two holes on either end.
5. And yes, I expect to chew thru a few blades, good advice to have some spares.