Grille Repair Jig

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User0511

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So I have a collection of broken grilles and driver quality Grilles. 76/77 Volare Grilles are rugged as hell and so are the 76/77 Aspen.

The 78/79 Aspen and Volare type grilles are like "A Christmas Story" Fra-Gil-eah and break just looking at them.

So I have been wanting to construct a jig that would simulate the front of an F body.
so here it is
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This allows me to lay it on a work bench or hang up my work to dry. It supports the weight of the grille and keeps it from collapsing in on itself. I took my known "good" grille as a mock up. This will allow grilles in 3 and 4 pieces a return to home position for the reconstructive surgery.
 
Fragile is an understatement. I'm always afraid I'll hit a fly and break a piece out. Seriously. Mine is half Gorilla Super Glue and epoxy I think. Everytime I look,,,,,,,,another crack.:( Also had to CAREFULLY bolt it on and slowly draw the parking lights in as it was warped (like too straight across). The center was good and the ends stuck out at least 1/2". Talk about a tense procedure!:eek: It was an NOS piece I got about 15 years ago from Marty and only been on the car since 2012 so it's not like it's been in the weather and sun very much. Probably why it's so hard to find a used '78/'79 grille that isn't broken or missing entire chunks.

That jig is how they need to be stored. As you said, the weight of the grille, which isn't much, will deform it.
 
Aspen500 said:
Fragile is an understatement. I'm always afraid I'll hit a fly and break a piece out. Seriously. Mine is half Gorilla Super Glue and epoxy I think. Everytime I look,,,,,,,,another crack.:( Also had to CAREFULLY bolt it on and slowly draw the parking lights in as it was warped (like too straight across). The center was good and the ends stuck out at least 1/2". Talk about a tense procedure!:eek: It was an NOS piece I got about 15 years ago from Marty and only been on the car since 2012 so it's not like it's been in the weather and sun very much. Probably why it's so hard to find a used '78/'79 grille that isn't broken or missing entire chunks.

That jig is how they need to be stored. As you said, the weight of the grille, which isn't much, will deform it.
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That 78 Volare Grille is the most flimsy yet. I'll sure it up the best I can and then store it on the Jig or make another jig in a protective box
 
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Just finished my own grill repair for my 77 wagon. I looked around online and could only find two suitable replacement grills. Both out of my price range, one was $800 and the other $300.

So I decided to use The original which actually broke into three pieces when I began removing it and fixing it. I used plastic epoxy to glue it all back together and I purchased an aftermarket grill kit.

I'll tell you what it's been hell trying to make it work, It still looks pretty rough but it's a far cry from what it was.
 
Leizurtime said:
View attachment 17849

Just finished my own grill repair for my 77 wagon. I looked around online and could only find two suitable replacement grills. Both out of my price range, one was $800 and the other $300.

So I decided to use The original which actually broke into three pieces when I began removing it and fixing it. I used plastic epoxy to glue it all back together and I purchased an aftermarket grill kit.

I'll tell you what it's been hell trying to make it work, It still looks pretty rough but it's a far cry from what it was.
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I know what you mean. That's why I built the jig. It keeps the work secure and stops it from walking all over the work bench. Try utilizing the plastic shavings with some acetone to build a cement that hold better than anything. use an old tuna can to mix it or low wide glass jar.

Still that looks great
 
This is one of many things, I wish someone in aftermarket would make a repop of.

I can’t see them not making their money back, on in a short time.
 
I tried the acetone and shavings on a flare and the plastic stayed soft. I never got real hard. Kinda turned to a rubber instead. What did I do wrong?
 
Are you sure you used ABS plastic shavings. I`ve been using the same technique to repair some damaged spoiler ends and have had no problems. If you are putting it on really thick or started with a really thin mixture then it will take quite a while (a week or more) to harden. It also tends to soften the area around the repair if you apply too much at one time.
 
maybe i didn`t give it enough drying time. i used a old spoiler and shaved pieces off of that. should i use new abs? if so where can I find it?
 
New ABS is the black plumbing drain pipe and fittings that you can buy at any hardware store. I have used pieces of an old broken grille with no problems.
 
I covered the pieces in acetone in a glass jar and let it soak until soft. Correct? Anything I `m missing? I`m going to try it again.
 
You actually need to completely dissolve the pieces or shavings in the acetone until you have a paste about the consistency of peanut butter. Then your good to go.
 
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