lasater

Here is how I did it. The first photo with the red rectangles shows the areas that I removed with a Bridgeport mill. I used the Bridgeport to make sure the cut was exactly parallel with the grid of the grill.

The second photo with the green rectangles shows the areas I used from the "donor" grill. These were simply cut with a band saw and squared up with 20" disc sander. The piece that filled the upper hole in the grille has a forward facing angle so I cut a vertical slot in the back side, used a heat gun to curve it and cemented it in place.

Minor imperfections were filled with bondo, filed flat and painted to match. The last photo shows the finished grill. Like I said in the beginning, this little mod has been waaaaay more work than anyone would imagine.

Cat Man HHR

Thanks for the explanation and pictures.

lasater

Just finished the shifter electrical. The park/neutral safety switches and the back up light switches took forever to get adjusted correctly. The p/n safety switch ties into the Ron Francis iStart ignition. Another system wired into the B&M Pro Ratchet shifter is the line lock push button on the shifter handle. The shifter has a black aluminum box like cover that hides the mechanism. The challenge is that you can't get the cover on over the shifter lever if the line lock button is installed and you can't put the line lock button on without the aluminum box cover.........that is a problem for tomorrow. As for me, I'm tired.
Here is a photo of the wired shifter.

whopper

Man, I wish I had your talent, skills and patience. :) Nice work man.

Oldblue

Very clean job! We used to use the term sanitary or sano, back in the day!

lasater

After an entire weekend of adjusting, re-adjusting, tracing wires and re-routing wires, the shifter is done. It doesn't look like much but here it is.

lasater

It's time to completely finish the rockers so I can cut the holes for the exhaust tips. As always final fitting is slow and painful. Here's where I am now.

Oldblue

Back to the old grind! The devil is in the details!

lasater

I haven't had the car outside much lately and stood back for a photo. Here is what the emblems look like.

Fox Hat

Awesome