a few people have been asking me about my leterbox, so i thought there would be enough interest for a DIY

1 get your hands on a TH grill, and only a TH grill, and seperate the backing,
you should have a power sander, preferably a small one, with a harsh grit paper, a medium and a fine grit paper for finishing.

2 Cut out the center piece, from the face, as close as you can to the surface, as this will minimise sanding
http://i304.photobucket.com/albums/nn177/lowridermagna/30012008.jpg

3 cut out a square from a CD case, its good if the plastic is clear, you could use purspecs
but a CD case is just easier, cut to shape, to sit neatly, (this is for top and bottom gaps)

http://i304.photobucket.com/albums/nn177/lowridermagna/30012008002.jpg

4 sand flat

5 more sanding

6 did i mention sanding?
http://i304.photobucket.com/albums/nn177/lowridermagna/30012008004.jpg

7 Use body filler,
*Dont be shy on the hardener,
*Dont sure too much bog at once, it goes rock hard, so its means more sanding, you can allways add more later,
* It does generate heat when hardening, so watch that.
*work quickly
* I used a plastic container to mix the bog in so once the bog dried hard, i could flex the container and the dried bog could pop out, so i could reuse the containter
*buy a pack of paddle pop sticks, very handly to use to mix with

8 use the filler to hold in the clear plastic, do not GLUE, i tried and it would just crack.
make sure there is no voids or air pockets behind it, thats why i used the clear plastic. as this underside you wont see, use a lot of bog, as it will give the grill strength, (dont over do it) it still needs to fit back on the car.

9 sand flat, and add more bog smears over the top to fill any tiny holes that the sanding has exposed, repeat untill smooth with no defects

http://i304.photobucket.com/albums/nn177/lowridermagna/31012008.jpg

10 cut out the slats in the black backing, but do not touch the outer part, as this is where the grill screws back together again, and will mount back onto the car.

11 cut out some mesh, i used black mesh, but you could use other colours if you want,
to the size just larger than the grills opening, so only have a tini overlap

12 now sandwich the mesh, in with the backing, and screw together, no need for glueing the mesh in.

13 i recommend painting by a pro, to keep the costs down, prep by sanding with wet n dry.

14 enjoy
http://i304.photobucket.com/albums/nn177/lowridermagna/DSC01690.jpg

THANKYOU!!! I have a spare TH grill sitting in my shed... think I might give this a go :)

hey man
any chances of photos of the backing support that holds the grill in?
did you sand the backing after you cut all the slats and middle support out?

So, from what I can see, it had to be the TH grill because of the depth of the bottom of the front of the grill? I don't see why you couldn't build a letterbox grill from a TF grill - would be a bit harder and take longer, but it should still work.

I have a TF grill in a garage, should stop talking and start trying.

Regards, Tony

So, from what I can see, it had to be the TH grill because of the depth of the bottom of the front of the grill? I don't see why you couldn't build a letterbox grill from a TF grill - would be a bit harder and take longer, but it should still work.

I have a TF grill in a garage, should stop talking and start trying.

Regards, Tony
That is it, the depth gives it its "letterbox" style
I would not bother using a TF Grille, it is pretty much flat, really, dont bother :P

Also, get a cork Sanding block, when sanding, this will even out all the surfaces for a nice smooth finish.

good now they'll annoy you instead of me:gtfo:


And yes you can only do this with a TH grill as it's 2 piece all the earlier ones are 1 piece.

And yes you can only do this with a TH grill as it's 2 piece all the earlier ones are 1 piece.

My TF grill is 2 piece, I took it apart about 1/2 hour ago. Absolutely filthy between the pieces too, might give them both a bath in degreaser. And I think I can see how to make a little bit of depth, but nothing like the TH. So maybe I won't go depth but make it bulge a little.

The mother in law is in town all next week, good reason to be in the garage trying to make a grill. lol

Regards, Tony

just for all interested
this is the backing part of the grill after all the mesh and middle bar is cut out
no body has a picture of this online, so i thought it might be helpful, because i would have liked to seen this before i attacked mine

but it came out perfect thankgod
:)

http://img510.imageshack.us/img510/9059/dscf1902nv0.jpg

assume this is the same, except instead of a TH you have to use a TS?

oh and for people doing this mod,
What I found really helpful when cutting the mesh to size is to start at one end cutting a little section at a time, once this is done cable tie it into place so it doesnt move and continue right around the grill, then while the cable ties are still on put the backing support on and screw in all the screws but not all the way, then cut the cable ties of and screw in the rest of the way

this way the grill is accurate and in the correct position

I got this advice of a sheetmetal worker who happened to be at my house when i was putting the mesh on

:)

assume this is the same, except instead of a TH you have to use a TS?
Wut

TS has the attachment points as part of the grille mate

could mods add this to sticky DIY's please?

Looks great, very neat

might go down to the wreckers and get myself a grille

Sweet, i'll be attempting one of these shortly :D

HI guys, new to AMC and looking at doing this for my first mod, just wondering will the TH grille fit a TE?

HI guys, new to AMC and looking at doing this for my first mod, just wondering will the TH grille fit a TE?

yes it will fit fine

yes it will fit fine
VK Commodore grilles fit aswell, just throwing that out there

so has anyone tried this not using a TH grille? if so, how did it turn out?

so has anyone tried this not using a TH grille? if so, how did it turn out?

Did it with a TJ grill, looks awsome. For anyone wanting to do anything like this, Bunnings sell an Ozito rotary tool (like a dremel) for $50. best 50 i ever spent. Makes the job so much easier.

Dremel saved me alot of time aswell, but be carefull its very easy to take off more than you intend with a dremel. Sand paper on a block is the safest and will always give the best finish if you got the time.

Did it with a TJ grill, looks awsome. For anyone wanting to do anything like this, Bunnings sell an Ozito rotary tool (like a dremel) for $50. best 50 i ever spent. Makes the job so much easier.

picsofgrillorban!!















(pics of grill or ban!!*)

i'll be making a letterbox grill of a TE, Over the holiday "the idea is to make it one piece with the brackets" i'll put some pictures

;960531']VK Commodore grilles fit aswell, just throwing that out there

How well do they fit, much modding needed? I've seen a VK Brocky grille on a TF before and It looked fricken sweet.

http://i.ebayimg.com/03/!Bg9(EhwCGk~$(KGrHqIOKjoEryZ14zGzBLHFMQ3!i!~~_12.J PG

How well do they fit, much modding needed? I've seen a VK Brocky grille on a TF before and It looked fricken sweet.

http://i.ebayimg.com/03/!Bg9(EhwCGk~$(KGrHqIOKjoEryZ14zGzBLHFMQ3!i!~~_12.J PG
i reckon that would be a easy mod, i TE or th grill could be use to make that..?

I saw a magna painted in that harliquin paint with one of those grilles on cardomain. For the life of me I can't find it.. but I could have sworn it was one of these grilles!

Bugger that, the top grille is where the radiator gets most of its airflow from, I wouldn't be plugging it up with a VK grille.

G'day Everyone,

The Reasons i've made a Letter box grill out of a TE instead of a TH grill is for 3 reasons
1. The brackets are stronger on the TE grill
2. Thicker on the top and sides, more Square
3. One piece Grill

I think your going to like it or hate it. but just another opinion for everyone

1. Try and get a good TE grill, As the brackets aren’t going to be changeable once you start fibre glassing
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1356
2.Cut out all the flins, and side section... straight forward, until you get to the side brackets.. good idea to take
your time. scratch the grill up with sand paper 80 /120
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1357
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1358
3. i'm using speaker cloth to make up for the gabs, becuase its one piece it means your not going to get cracks from movement.
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1359
4. Using a paint brush to spread the Resin even over the whole front of the grill and the speaker cloth
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1363
5. BOG, Got to love the stuff.
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1361
6. Hamishs car ( UNDER8D has a TH Letterbox ) in his hand is the TE Letterbox
http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1362
i'll put a completed picture up when its done

Yeah...Dunno why you like doing everything the opposite but with the TH grille you just cut out the middle slat, 15 mins of fibreglassing and your done, you've basically had to make a WHOLE grille from scratch, I'd still be advising people to use a TH grille. I've made about 6 of the things now and wel your just making more work for yourself.

Why the need for stronger brackets? Ive never had any problems with the TH grilles.

;1181411']Yeah...Dunno why you like doing everything the opposite but with the TH grille you just cut out the middle slat, 15 mins of fibreglassing and your done, you've basically had to make a WHOLE grille from scratch, I'd still be advising people to use a TH grille. I've made about 6 of the things now and wel your just making more work for yourself.

Why the need for stronger brackets? Ive never had any problems with the TH grilles.

I've had problems in the past with my TH grill brackets, and so has hamish. Mainly because you can still see the plastic support unless you cut it super thin, and it just makes it alot weaker and never seems to line up square.

Completely right, Alot more work has to go into it... but nothing extreme, all about making another opinion.. be making a VK look alike soon as well, i'll post it up:woot:

http://www.aussiemagna.com/forums/picture.php?albumid=192&pictureid=1384
Grill in Primer

love the grille mate top stuff!

That grille looks awesome. tutorial is very clear to understand. if u end up puttin mesh on take another pic would love to see what it looks like meshed

that's awesome :thumbsup:

looks good mate! i wonder if you could put that EL wire? i think its called around the edge ( the stuff in limos?) pretty ricey but would be different haha

How well do they fit, much modding needed? I've seen a VK Brocky grille on a TF before and It looked fricken sweet.

http://i.ebayimg.com/03/!Bg9(EhwCGk~$(KGrHqIOKjoEryZ14zGzBLHFMQ3!i!~~_12.J PG



Found it!! Not quite VK looking as I thought, but it was a while ago. Where's this grille from and how do I get one?? :D

http://img35.imageshack.us/img35/1619/lookatme.jpg

The grille on that car was a one-off, it was for the TJ Sportswagon prototype I believe, you'd need to get the VIN, but I doubt there'd be any spares...

so i got a question im planning on doing one my self but the thing is that i dont have and fiber glass stuff ... so i was wondering if there is any round revesby are that i could borrow some of or even help me out to do it ???

Go to supercheap and get some fibreglass filler....thats all ya use. its like bog but with fibreglass pieces mixed in with it

I am a little late to this party, as i see this thread is quite old. However i was just wondering, will a TH grill fit my '97 Verada KE? Im looking to make one of these grills up for my wagon. Cheers.

I am a little late to this party, as i see this thread is quite old. However i was just wondering, will a TH grill fit my '97 Verada KE? Im looking to make one of these grills up for my wagon. Cheers.

Yes it will fit no probs.

Yeah, both will fit, don't go cutting up yours grill, buy a cheapy from the wreckers, make sure the brackets are in good Nick

Hey I kno this is a little bit off topic but wer do you get those insane eyebrows that u have on your vrx... I also just bought my th grille and I'm giving the letterbox grille a go this weekend!!!
Thanks

they were a one off batch that was made by a member here a few years ago, so impossible to get unless a member sells a set they have

Oh ok spewing..... Hmm well if anyone's keen on selling them I'll pay top dollar :D