How to...Make a USDM "Zenki Aero" Grill

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02-06-2007, 10:09 PM
G-spot

How to...Make a USDM "Zenki Aero" Grill

This is not a new thing since quite a handful TGCers have done this with different techniques in the past few months. It's basically a USDM 1999-2001 grill converted into a Zenki Aero grille found in JDM Galants/Legnum. Note: this mod can be applied to a JDM grill if so desired
***Disclaimer: I'm not responsible for any loss or damages done to your grills.

Here are pics of a REAL JDM Zenki Aero Grill:
http://i16.photobucket.com/albums/b2...e/DSC00521.jpg
http://img234.imageshack.us/img234/535/grill3.jpg
http://www.jin.ne.jp/route-s/image14111.jpg
http://memimage.cardomain.net/member...05_83_full.jpg

Here are USDM "Zenki Aero" Grill from various TGC members:

Speedracer
http://i37.photobucket.com/albums/e6...wcarpix025.jpg

G-spot
http://i70.photobucket.com/albums/i9...tgc/zenki1.jpg

http://memimage.cardomain.net/member...828_4_full.jpg

There are several ways to fill in the gaps: Bondo, Fiberglass, or Steel putty. I've chose the steel putty because of it's fast drying time.

List of material:

USDM 99-01 grill (prefer already jdm modded to cut down time)
Hack saw or
Diamond jewel cutter or
Dremel diamond cutter
Body filler (bondo, fiberglass/resin/hardner, or steel putty will do)
sand paper (200-800 grit)
glaze putty

Stock Grill
http://img.photobucket.com/albums/v2...e/IMG_1317.jpg
First cut the fins or gills (if not done so already), and it should look like this:
http://img.photobucket.com/albums/v2...buy/grill2.jpg

Next, using a cuting device (your choice), cut the center piece. Don't worry about eveness since the sandpaper and body filler fills the uneven marks for you.
http://img.photobucket.com/albums/v2...o/DSC_0005.jpg

Sounds easy? If you have experience with simple body work then this tutorial is a breeze but if this your first time it's recommended to have someone guiding you with some knowledge of intermediate body work.
If anyone has other tutorials on this subject please feel free to share it.

Enjoy.
02-07-2007, 01:18 AM
milo111000

what fillers would be best to use??
02-07-2007, 01:26 AM
njjfudge

Love the first pic G-Spot 8)
02-07-2007, 10:21 AM
G-spot

Quote:

Originally Posted by milo111000

what fillers would be best to use??

most prefer Bondo brands it's pretty much what can handle the "stress" when pressed against the weight of the hood. Fiberglass tends to crack with too much flex but the steel putty can hold it like abs plastic. Of course you can use abs plastic gel like the ones body shops use for bumper repairs.
02-07-2007, 11:47 AM
Jeffylou87

sounds very easy... I have an extra grille I think I'll do that when I have some spare time.. when I get bored of the grille I have on there...
02-07-2007, 11:50 AM
bronxbombr

nice going dude :!:
02-07-2007, 01:57 PM
n3oAcid24

Re: How to...Make a USDM "Zenki Aero" Grill

Quote:

Originally Posted by G-spot

Stock Grill
http://img.photobucket.com/albums/v2...e/IMG_1317.jpg
First cut the fins or gills (if not done so already), and it should look like this:
http://img.photobucket.com/albums/v2...buy/grill2.jpg

thats my car and my painted grill....... :D :D :D :D :D :D i feel so important... LOL.....
02-07-2007, 02:10 PM
furiousgtz

Re: How to...Make a USDM "Zenki Aero" Grill

Quote:

Originally Posted by n3oAcid24

Quote:

Originally Posted by G-spot

Stock Grill
http://img.photobucket.com/albums/v2...e/IMG_1317.jpg
First cut the fins or gills (if not done so already), and it should look like this:
http://img.photobucket.com/albums/v2...buy/grill2.jpg

thats my car and my painted grill....... :D :D :D :D :D :D i feel so important... LOL.....

look at phil man he is pissed
02-07-2007, 02:17 PM
n3oAcid24

Re: How to...Make a USDM "Zenki Aero" Grill

Quote:

Originally Posted by furiousgtz

Quote:

Originally Posted by n3oAcid24

Quote:

Originally Posted by G-spot

Stock Grill
http://img.photobucket.com/albums/v2...e/IMG_1317.jpg
First cut the fins or gills (if not done so already), and it should look like this:
http://img.photobucket.com/albums/v2...buy/grill2.jpg

thats my car and my painted grill....... :D :D :D :D :D :D i feel so important... LOL.....

look at phil man he is pissed

thats his wannabe thug look!!!!! LOL....
02-07-2007, 05:25 PM
Reelax

http://www.jin.ne.jp/route-s/image14111.jpg

that is not the "zenki aero" grill. it actually is a nifty-r grill and is fiberglass like the liberal grill.
02-07-2007, 08:59 PM
Kalamidad

Re: How to...Make a USDM "Zenki Aero" Grill

Quote:

Originally Posted by n3oAcid24

Quote:

Originally Posted by furiousgtz

Quote:

Originally Posted by n3oAcid24

Quote:

Originally Posted by G-spot

Stock Grill
http://img.photobucket.com/albums/v2...e/IMG_1317.jpg
First cut the fins or gills (if not done so already), and it should look like this:
http://img.photobucket.com/albums/v2...buy/grill2.jpg

thats my car and my painted grill....... :D :D :D :D :D :D i feel so important... LOL.....

look at phil man he is pissed

thats his wannabe thug look!!!!! LOL....

he looks tini compared to the size of that grill.

Very nice Peter. I wanna see it in person though.
02-08-2007, 01:11 PM
n3oAcid24

Re: How to...Make a USDM "Zenki Aero" Grill

Quote:

Originally Posted by Kalamidad

Quote:

Originally Posted by n3oAcid24

Quote:

Originally Posted by furiousgtz

Quote:

Originally Posted by n3oAcid24

Quote:

Originally Posted by G-spot

Stock Grill
http://img.photobucket.com/albums/v2...e/IMG_1317.jpg
First cut the fins or gills (if not done so already), and it should look like this:
http://img.photobucket.com/albums/v2...buy/grill2.jpg

thats my car and my painted grill....... :D :D :D :D :D :D i feel so important... LOL.....

look at phil man he is pissed

thats his wannabe thug look!!!!! LOL....

he looks tini compared to the size of that grill.

Very nice Peter. I wanna see it in person though.

i guess that was picture was taken on one of his skinny looking days. lol......

man G-Spot, i thought my grill looked good. shoot, yours looks crazy. now im thinking of going with that look... nice job.
02-19-2007, 02:44 PM
Phil

you whore!!!! Im down 20 pounds so far in the last two months. Im gonna try this grill as soon as my grille comes back.
08-20-2007, 06:14 PM
xxarmandxx

alrite this looks really good, but i had a guestion since i want to do this. on the stock grill there is the emblem right? if you were to the cut that center peice in a straight line a little bit of the emblem would still show. did you use body filler to fill that little hole up? i was just curious before i do this?

and one more guestion, i'm pretty sure i read somewhere in here u painted it. how did it come out since the grill is plastic, because my is hte stock chrome color, but i want to paint it red to match my car.
08-21-2007, 12:19 AM
SLS2000

I used fiberglass. The absolute best advice I can give you is that the chrome has to be sanded down to the gray plastic in order for the fiberglass to hold on. Half of the top diamond will have to be grinded until you see the gray plastic then fill it in with either fiberglass, plastic filler, etc. Again the chrome must be gone in order for these things to stick. You bridge the large gaps with fiberglass, maybe two layers for it to be rigid. the rest you can fill in with bondo. The least bondo you use the better cause as you probably know that area shakes real good. Prime, sand, prime, sand , paint , sand, paint sand, paint.

Good luck.
12-05-2007, 11:21 PM
Eclipse97526

here is my grille i did back in august ;) i prefer bondo hehe, it was very forgiving for a first timer ;) this was after the second coat was fogged on, still had 2 more coats, and clear. if i could do it again, i would have wet sanded. Definatly remove the chrome coating , or it peels VERY easy. and wont last at all.

http://i126.photobucket.com/albums/p...21-07_2033.jpg
12-15-2007, 02:41 AM
projectGTZ

nevermind
01-08-2008, 10:35 PM
Chaps

here's the grill i made. great tutorial!

https://www.thegalantcenter.org/gara...y&image_id=837
01-09-2008, 11:49 PM
djflex167

nice!!
01-10-2008, 01:03 AM
spdracr

here is mine but its not done i still have to sand it all the way down and paint it and then put some mesh

http://i233.photobucket.com/albums/e.../DSC00002a.jpg

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