Had a long think I thought stuff it I'm going to go big mouth seeing the bumper is going to be off the car for awhile with the rebuild and all so now is a good time and don't have to rush it really. The bumper is not mint condition so I'm not worried to much if I change my mind in the future I will just get a new bumper.

So now to the point, what tools etc will make this job easy for me? I have a dremel with thousands of different bits, I'm guessing this is pretty much all I need to just cut the lugs things off neatly and maybe a small smooth file? I cant find any guide as such for this which I'm surprised at so I might take some step by step pics for others, although I'm guessing its not going to be rocket science but would be nice for a reference.

Finally I want some nice black mesh thats makes the hole look really dark at a distance like some peoples I have seen on here not the chicken wire looking stuff. Now just fixing it to the bumper, is this just bonded on from the inside lip or is there a better more secure way of doing it?

Thanks all, Joe.

I did mine at work. I chopped the main lump out with an air saw then did the intricate bits with with a belt sander. If your gonna have it painted I would go over the edges where you've dremeled, belt sanded etc with some 320-400 grit paper to make it a better finish. I left the lugs in the middle at the bottom to melt to the mesh when it goes in.

When I put my mesh in I used body sealer and the lug at the bottom melted, and left it overnight to set, and it does the job just fine. I got my mesh off of eBay from a Polish company, and it cost £15 delivered.

Hope that helps

Hi I have a question what about the front crash bar I have seen some with them and some with out. How easy is remove and is it practical?

Cheers jp, i seen the polish mesh after looking at your car thread i think i will be going with the style begining with k i cant remeber the name haha

I just needed black mesh quickly and the right size, thank god for eBay. Also the Mesh was delivered to my door in 2-3days after purchase.

The crash is easy to remove when the bumpers off. But if you chose to chop it to fit the intercooler, the strength of the car in a front end impact is compromised quite a lot. I'm not too bothered in all fairness, as long as it looks the part

Im pretty sure the most of mine was just cut out with a brand new stanley blade. There are loads of points on the inside of the bumper to attach the mesh to, best way to do it is leave excess mesh at the bottom, remove the little bracket things that are just screwed to the bumper, place mesh down and then replace the little brackets through the mesh

started the big mouth today, very easy job I found using a hacksaw blade in a handle and a stanley blade to make mince meet of the job. Just need to file down the rough edges and fit the mesh once it has arrived.

Also took step by step pictures so will hopefully get a guide together for others to reference.

Yes that would be great could you let me no when u have don't that many thank

I'd like to see the guide as I am very tempted to do this myself as I'm fitting a THS intercooler next weekend and think the car would suit the look of the big mouth grill better

Oh and just a quick question, how thick is the metal that makes up the crash bar?As I was thinking of drilling some circular holes in the bar to aid flow to the cooler and then use a flaring tool to add strengthen back to it

Im pretty sure the most of mine was just cut out with a brand new stanley blade. There are loads of points on the inside of the bumper to attach the mesh to, best way to do it is leave excess mesh at the bottom, remove the little bracket things that are just screwed to the bumper, place mesh down and then replace the little brackets through the mesh

I do not have these little bracket things on the bottom or holes where any would of been. my mesh should be here tomorrow so should be done this weekend.