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Has anyone removed the front grill from the stock bumper? I am having an intercooler installed and I would like to remove the front grill. It looks like I could use a Dremel tool with some kind of cutting wheel to cut it out then sand it smooth and repaint. Anyone done this? Posting some pics would be a big +.
Just remember when you are cutting to go very slowly. The knife can easily veer off in the wrong direction and make the hole very crooked. I did mine with the front end off of the car. I set it on sawhorses with the grill facing up. Sorry no pics handy.
I removed mine using a hack saw blade and the followed with a dremel to get the remaining stubs. On my '05 after the grill was removed there were "V" gaps in the rim that runs around the grill location. The "ribs" of the grill are open in the back and from a "V" facing forward. When you cut them off the base will have a V gap where you have removed each rib. They're not that big or deep on the vertical ribs as they're smaller but the horizontal ones are fairly large.
dont you guys worry about your intercoolers getting beat all to hell?
I have been driving with it like that for 18 months and other than dead bugs, etc., it looks pretty good. I have had to clean the aluminum end tanks a few times and they get fairly dirty.