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Old 09-02-2001, 06:56 PM   #1
thermal
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Join Date: Aug 2001
Location: My Garage, Va.
Posts: 5,548
custom grill-6th gen civics

sorry, i typed in caps from microsoft word

CUSTOM GRILL 6TH GENERATION CIVIC

DISCLAIMER: THE WORDS WRITTEN BELOW ARE BASED SOLELY ON MY PERSONAL EXPERIENCE. IT IS NOT A “TEXT BOOK” PROCEDURE. I WILL NOT BE RESPONSIBLE FOR ANY MISHAP AND/OR CAR DAMAGE THAT MAY OCCUR DURING THE PROJECT. USE COMMON SENSE TO PRACTICE SAFETY. ENJOY AND GOODLUCK.
-Thermalfi’d16-

NOTE: REVIEW THE STEPS PRIOR TO PROCEDING WITH THE PROJECT.

COST:
- BETWEEN $5 TO $20 DEPENDING ON THE GRILL OF YOUR CHOICE.

ELAPSED TIME:
- 2 TO 3 HOURS

TOOLS:
- METRIC WRENCHES OR SOCKET SET.
- PHILLIPS SCREW DRIVER
- PENCIL
- AVIATION CUTTING NIPES OR SHEET METAL CUTTER
- WIRE CUTTER
- FLAT HEAD SCREW DRIVER
- UTILITY KNIFE
- FILE (OPTIONAL)
- MARKER

MATERIALS:
- GRILL OF YOUR CHOICE (I USED A PATIO DOOR GRILL FROM THE HARDWARE STORE)
- PICTURE HANGING WIRE
- ASSORTED SHEET METAL SCREWS (SHORT ONES AND STAINLESS)
- SMALL FLAT/FENDER WASHERS

STEPS:
UNBOLT AND REMOVE THE BUMPER TO A LOCATION WHERE IT WILL NOT BE SCRATCH DURING THE PROCESS.

TOP SECTION: THIS IS THE MOST CHALLENGING PART.
THIS IS A 3 PIECE SECTION.
-BUMPER
-FRONT TOP FRAME
-REAR TOP FRAME

1. REMOVE THE TOP SECTION FROM THE BUMPER
2. DISASSEMBLE THE TOP SECTION. IT SHOULD BE TWO PIECE (FRONT AND BACK).
3. PLACE THE FRONT FRAME (WHICH IS THE PAINTED SECTION) OVER THE GRILL OF YOUR CHOICE AND USE IT AS A “GUIDE” TO MEASURE AND SHAPE THE GRILL FOR THE TOP SECTION. ENSURE TO LEAVE EXCESS AREAS (AT LEAST 1 ½ INCH) ALL AROUND TO COMPENSATE WITH THE FITTING PROCESS.
4. CUT THE GRILL AROUND NEATLY.
5. NOW, THIS IS THE TRICKIEST PART. IT WILL MAKE MORE SENSE ONCE THE BUMPER DISASSEMBLY IS COMPLETE.
6. THE PURPOSE OF THE NEXT STEPS WILL BE TO CREATE A FRAME THAT WILL HOLD THE GRILL IN PLACE. YOU ARE GOING TO REPLACE THE “H” EMBLEM AREA WITH THE GRILL. CUT THE “H” EMBLEM AREA BY CONDUCTING THE NEXT FEW PROCEDURES.
7. TAKE THE REAR PIECE OF THE TOP FRAME. FACE THE FRAME TOWARDS YOU. WITH THE PENCIL, CREATE A 1 INCH OUTLINE ALONG THE EDGES THAT STRECHES FROM CORNER TO CORNER. USING THE UTILITY KNIFE, CUT FROM THE INSIDE OF THE FRAME FROM CORNER TO CORNER, THEN HORIZONTALLY TO SAVE THE FRAME. THIS SHOULD GET RID OF THE MOUNTING AREA OF THE “H” EMBLEM AND THE HORIZONTAL RAILS.
8. THERE WILL BE SCREWS ALONG THE BACK OF THE FRAME. TRY NOT TO RID ALL OF IT DURING THE CUTTING PROCESS. THOSE SCREWS WILL BE USED TO SECURE THE GRILL.
9. FILE THE EDGES AS NECESSARY TO CREATE A MORE EVEN CUT.
10. PLACE THE GRILL BEHIND THE REAR FRAME. CAREFULLY AND NEATLY MOLD THE EDGES OF THE GRILL TO THE BACK OF THE REAR FRAME.
11. SECURE THE GRILL USING THE PICTURE HANGING WIRE OR SHORT SCREWS. THE PICTURE HANGING WIRES CAN BE TIED AROUND THE EXISTING SCREWS BEHIND THE FRAME.
12. CUT ANY EXCESS GRILL.
13. RE-ASSEMBLE THE BUMPER.
14. RE-INSTALL THE BUMPER TO THE CAR.

BOTTOM SECTION:

1. KEEP THE BUMPER UN-INSTALLED.
2. YOU CAN EITHER CUT THE RAILS USING THE UTILITY KNIFE OR PUT THE GRILL OVER (WHICH WAS MY CHOICE),
3. IF YOU CHOOSE TO CUT THE HORIZONTAL RAILS, MAKE SURE YOU CUT THE RAILS AS NEAT AS POSSIBLE. IF RUGGED EDGES ARE PRESENT, USE THE FILE TO EVEN IT.
4. PLACE THE GRILL BEHIND THE BUMPER AND MOLD THE CORNERS.
5. SECURE THE GRILL BY USING A SERIES OF COMBINED FLAT WASHER AND SHORT SCREW. MAKE SURE THE SCREWS DO NOT PROTRUDE THE BUMPER FRONT SURFACE. THAT IS THE REASON FOR UTILIZING SHORT SCREWS.
6. IF YOU CHOOSE TO PUT THE GRILL OVER THE RAILS, SECURE IT WITH THE PICTURE HANGING WIRE AGAINST THE RAILS.
7. RE-INSTALL THE BUMPER TO THE CAR.

BOTTOM CORNERS: (for 99-00 civics only)

1. THE BRAKE COOLING VENTS THAT ARE LOCATED ON THE BOTTOM BUMPER CORNERS CAN ALSO BE CUT AND REPLACED BY A GRILL. SECURE THE GRILL BEHIND THE BUMPER AS STATED ABOVE, ON THE BOTTOM SECTION PROCEDURE.

The Finished Product:





DIRECT YOUR QUESTIONS TO:
thermal99@excite.com
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