I hit a pheasant and a few weeks later I washed my car and some of my grill fell out 
They are £43 from the dealers as you need both sides. Since I'd aquired an open cone filter I thought I may aswell make this hole bigger and make some use from it. Here's what I did...
First of all I made a template for the air funnel. Normally you wouldn't really bother doing this but as I had to get it in an exact position I thought this was the best answer. I then checked that the template was correct...
Next I offered the funnel up against the grill to see how it might look. I wasn't sure about the silver, it looked a bit chav :roll: so I sprayed it with the closest paint match I could find from memory. Before and after...
I took the template and held it in position whilst marking the area to be removed with an unamed white correction fluid
I needed a way of removing the plastic without risking cracking it further so my weapon of choice was a soldering iron! The photos tell the story...
My engine bay is a real pig. With an intercooler and radiator crammed into the front grill, space was an issue. I found a way through to the front but it meant squashing up the pipe and doing a couple of tight bends with the ducting. A few scraped fingers later, I got the ducting to the grill. It wasn't ideal but i tested it by blowing into the ducting and felt it come out the other end no problem. Because of the depth issue I had to cut most of the length from the funnel. I cable tied the ducting pipe to the front grill by piercing small holes in the pipe on both sides. I then routed the ducting to the air filter and is held in place by the battery (which I moved slightly) and also the oil breather filter which I cable tied in a new position above it. I also had some 70mm ducting which I cable tied next to the filter and routed it down the wing and secured it down at road level to scoop plenty of air...
The finished item with relocated badge...
It's better than the hole that was there before and now serves a purpose but I'm not sure if I'm totally happy about how much the funnel sticks out from the grill. I might experiment on the spare funnel to reduce it's depth.
They are £43 from the dealers as you need both sides. Since I'd aquired an open cone filter I thought I may aswell make this hole bigger and make some use from it. Here's what I did...First of all I made a template for the air funnel. Normally you wouldn't really bother doing this but as I had to get it in an exact position I thought this was the best answer. I then checked that the template was correct...
Next I offered the funnel up against the grill to see how it might look. I wasn't sure about the silver, it looked a bit chav :roll: so I sprayed it with the closest paint match I could find from memory. Before and after...
I took the template and held it in position whilst marking the area to be removed with an unamed white correction fluid
I needed a way of removing the plastic without risking cracking it further so my weapon of choice was a soldering iron! The photos tell the story...
My engine bay is a real pig. With an intercooler and radiator crammed into the front grill, space was an issue. I found a way through to the front but it meant squashing up the pipe and doing a couple of tight bends with the ducting. A few scraped fingers later, I got the ducting to the grill. It wasn't ideal but i tested it by blowing into the ducting and felt it come out the other end no problem. Because of the depth issue I had to cut most of the length from the funnel. I cable tied the ducting pipe to the front grill by piercing small holes in the pipe on both sides. I then routed the ducting to the air filter and is held in place by the battery (which I moved slightly) and also the oil breather filter which I cable tied in a new position above it. I also had some 70mm ducting which I cable tied next to the filter and routed it down the wing and secured it down at road level to scoop plenty of air...
The finished item with relocated badge...
It's better than the hole that was there before and now serves a purpose but I'm not sure if I'm totally happy about how much the funnel sticks out from the grill. I might experiment on the spare funnel to reduce it's depth.
