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| Fortunately, the top rail of the grille is hidden beneath the leading edge of the bonnet. |
I had initially thought that P3P's grille looked okay. However, closer inspection revealed that the entire top was either badly cracked or had broken off, most likely because there's no bonnet prop or catch keeping it from hinging too far forward. Why this is missing is anyone's guess and where I'm going to find a replacement is quite the conundrum, as a thorough search of the interweb has failed to locate one anywhere. So, if you do happen to have a spare, ... .  |
| Removed from car. Note the damage to the area above the driver's side inner headlight and to the top rail. |
We digress. Further searches of eBay and similar sites did reveal several replacement grilles, ranging in price from around $AU200 through to a rather less reasonable $350 or so, all with exorbitant postage and handling charges that in some cases went close to doubling their prices! Needless to say, I've got better sh*t to spend my resto budget on! |
| Driver's side showing damage above inner headlight. |
Things weren't looking too bright for P3P's aesthetics as my mind turned to possibly salvaging the headlight surrounds and trying to fold a section of steel mesh to protect the radiator and hide the horns, etc. It then occurred to me that if I sacrificed what was left of the top rail of the grille - which is almost invisible, being tucked under the overhang of the leading edge of the bonnet - there might be enough plastic to reconstruct the other damaged areas.
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| A closer view of the driver's side of the top rail. |
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| Passenger's side of the top rail, including cracked area above that side's inner headlight. |
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| Closer view of cracks above inner passenger's side headlight. |
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| Top rail removed. |
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Second rail filled and rubbed back.
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A few measurements later, it looked like the plan was feasible - as long as there were no mistakes - because there really were literally only millimetres of spare plastic available from what remained of the broken top rail. The busted bits were removed with a hacksaw blade and set aside.
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| Top rail |
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| The 'donor' pieces cut from the top rail of the grille. |
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| Top view of damage to area above inner driver's side headlight. |
A set-square and very flat, flexible steel rule were then used to mark out the cutting lines around the damaged areas of the driver's side, providing quite precise 90° angles that would be easy to replicate on the patch panels (they're squarer than they look in the photos). The cut faces were coarsely filed to ensure that they were two-dimensionally square and to produce a surface that the superglue would bite into and bond with. |
| Damaged area cut out. |
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| Patch panel marked out, ready for cutting. |
The donor plastic was then marked up to match the excision and cut to the outer side of the lines, allowing a bit of excess material that could be filed back to size. It was then cut, offered up to the area needing repair, and gradually filed until it was a good fit. |
| Offered up for the first time. |
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| Filed for a better fit. |
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| Offered up for the second time. |
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| Glued. |
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| Additional finishing panel glued on and filled. |
Once I was satisfied with the fit, the patch panel was superglued into position, clamped and left to set. Filler was then applied and rubbed back, and an additional finishing panel was added to the inner (medial) part of the grille to soften and integrate the look of the area where the top rail had been removed.
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| Filled and rubbed flat, ready for primer. |
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| Front view. The join is at the 11:00 o'clock position. |
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| Same side, viewed from below (join at 5 o'clock). |
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| Crack above the inner passenger's side headlight. |
Repairing the passenger's side was easier; it hadn't broken off, so it only needed to be glued and clamped. It also received a symmetrical version of the finishing patch that had been applied to the driver's side.  |
| Top view of crack above inner passenger's side headlight, glued together. |
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| Additional finishing panel, glued and filled but not yet sanded. |
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| The nearly finished product (needs a final rub-back, primer and paint). |
There's still a tiny bit of filling and rubbing back to do, before the whole thing can be primed and painted, but I'm very happy with the result so far. It'll be finished in the original semi-matte silver and the area behind it painted black, as will the central tabs that help to hold the grille in place. With the top being out of view below the bonnet, it should look like new!
Did you enjoy this post? If so, how about viewing Parts 1, 2 and 3 of Project 3P? Or, even better, why not check out the rest of uppermiddlepetrolhead.blogspot.com.au? There are hundreds and hundreds of classic, sports and performance cars featured, so you're bound to find something that you'll enjoy.
U M P H
(uppermiddlepetrolhead.blogspot.com.au.)
All iPhone images.
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