Badgeless R32 grill (almost)

[73landau]

My project was to create a VWless grill for a Mk5 R32. First step was to find some grills for experimenting with. Thanks to John and Ibrahims younger brother, I have the donor parts. Options for inserting the slats included glueing and welding. I went for chemical welding with tetrahydrofuran and some 480 loctite to fill small imperfections. Acrylic glue from RS components is close to THF and works in the same way. It disolves the plastic into a liquid state so it can be squeezed together and than it resets slowly.
I used paper clips to hold pieces together to set overnight in each step. I used the slats from the bottom section to reinforce each upper slat to add strength. I then "welded" on the slats from the donor grill on the reinforced section.
I inserted an upright rib in order to add strength.
Grill was then painted with Krylon Fusion satin black. Chrome stips were made from door edge guards and trimmed to fit original grooves

All the pics so far are in this link with lots of pics. Pics in reverse order.
http://photobucket.com/gregs_r32_grill

Some selected pics to keep the post a reasonable length.

Grill with bits removed and first reinforcing bits.
http://i229.photobucket.com/albums/ee278/73landau/r32 grill/IMG_0297.jpg

rear view with reinforcing. Not overly pretty, but the radiator shouldnt care :-D
http://i229.photobucket.com/albums/ee278/73landau/r32 grill/IMG_0316.jpg

Repainted grill with chrome strips and R32 badge
http://i229.photobucket.com/albums/ee278/73landau/r32 grill/IMG_0326.jpg

[73landau]

Shortened number plate holder previously made.
http://i229.photobucket.com/albums/ee278/73landau/IMG092.jpg

[Blu32]

Looks like a neat job - interested to see how it looks on the car.

Are you planning on filling in the leading edge of the bonnet?

[Rob32R]

Looks nice Greg, when are you getting an R32?

[GBJ-R32]

man this turned out nice, well done

[73landau]

I am of two minds with the bonnet. One is to fill the notch with metal and the other is to use a trim on the leading edge that covers it. The trim can be made and shaped out of ABS without too much difficulty.
As for an R32, I now have a house on the market in Warnervale. When it is sold, I will start a serious search. There are some nice examples with low kms on the market, but they will probably be sold before the house is sold :-(

[stefans]

Considered ditching the number plate holder completely?

[Rob32R]

Start your own business on badgeless grille's.

Many on this forum will put there hand up for one including me.

[stefans]

I'd be keen for a reasonable price

[73landau]

I don't.think anyone would buy one when you factor in labour cost :-) Like most custom mods , it is many more hours than most would pay. Two grills and about forty hours. .......

[stefans]

Haha, so 4-5k minimum! Just sell me yours? haha

[stephen8512]

wow thats clean! well done mate!

[Nathan_b]

Very impressive - wish I had the skills/knowledge to complete this!

If you change your mind re: purchase of an R32 I would pay good money for it :)