Im looking to make a letterbox grille for my '97 Ke Verada, im just wondering how difficult they actually are to make? If i was able to find a grille in decent condition, is it a simple as cutting out everything you dont want, then sanding smooth and re-painting the grille? Any information regarding the construction of the grille or previous experience making one would be helpful. I really just want to make sure i am able to make the grille into a letterbox before i go out and buy a grille. Cheers.

A bit of work involved mate, if you plastic weld in the gaps, you'll need to use the same ABS plastic as the that is the plastic used on the grilles or you could fibre glass fill in the sections then soft filler(bog) to get the shape unless you got the fibreglass to a good thickness but make sure the surface is nicely roughed up for the fibreglass to stick.
You'll need a few good tools to plastic weld but if your not bad with fibreglass, try that option.
Cut the mesh backing hollow then use any mesh desired.

Thanks for that, i have used fibreglass before (not on a car however), and ive seen the aplication and processes of using bog, and i reckon that method will be the best for me. I will keep my eye's out for a grille for sale, and then i will get started on it. Thanks for the info.

Search and you will find . http://www.aussiemagna.com/forums/showthread.php?t=63126&highlight=DIY+letterbox

AAAAAAARRRRRRGGGGGHHHH I searched for information on this but i found nothing! Sorry about that, if a Moderator is floating around feel free to delete this thread.