I couldn't bring myself to pay $250 for the RBS, or $150 for an ebay knock off that never fits, so I decided to make my own.
I've never done anything like this before so it was def a learning experience
This is how I did it....
THINGS YOU WILL NEED
1. Dremel or the like and a accessory kit
2. Sand Paper, 3 levels, light, medium and heavy
3. Screw Driver
4. Super glue
5. Eye protection
6. spray paint (primer, metallic color and clear coat)
7. Bondo kit
8 metal body patch
9. Gutter, honey comb mesh (6" x 2')
10. zip ties
11. Paper clips
Use the dremel to remove the inside:
This is the hardest part.... have patience and do this in a well ventilated area.
Use the grinder tool to smooth all of the edges, be careful not to grind to deep or you will have to fill in the holes.
Once your satisfied with your sanding and all of the edges are smooth. Take a shower. no really... put the grill under running water to remove all of the dust.
BONDO TIME!!!! make sure you do this in a well ventilated area or you will get sick or high or a combination of the 2
Take the metal patch and place it over the four holes and cut to size:
next, paper clip them on, this will hold them in place.
Now this is the tough part..... BONDO over the paper clips.... you have to wait no more than 5 minutes then pull the paper-clips off before the bondo sets.... if you don't
you will have to saw them out. The BONDO should hold the mesh and break apart to let the clips out.
Once the bondo dries, sand it down using the dremel with this bit
be careful not to go to deep, use the sand paper if needed.
it should end up looking like this
Step 5. Once all the bondo is done, drill holes on the top inside for the zip ties to attach the mesh like this:
Sand again with high grit, them medium grit, then low grit
Wipe down the grill with a moist cloth to remove all of the dust.
Apply 3 thin coats of primer, ensure the entire grill is covered and you can't see any chrome or black plastic, do the same to the mesh, let dry
Next, apply 3 good coats of the color of your choice, let dry
Next, apply 3 good coats of clear coat, let dry.