R50/R53 :: Hatch Talk (2002-2006) Cooper (R50) and Cooper S (R53) hatchback discussion.

R50/53 installing bottom aero grill

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Old Feb 7, 2008 | 11:14 PM
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installing bottom aero grill

Hey guys im about to put on my bottom aero grill. After reading all these post on how to install them im deciding that im gonna to do it with the bumper on removing the stock and putting the new grill in. Is there anything else i should be aware of when cutting. Just dont want to mess up the bumper.. Thanks
 
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Old Feb 8, 2008 | 12:32 AM
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Old Feb 8, 2008 | 12:05 PM
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i did it all with the bumper on the car. All you need is a razor knive and a steady hand.
 
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Old Feb 8, 2008 | 01:13 PM
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I removed the bumper. Be sure to set it on something soft like a blanket. It's really easy to remove the old grill once the bumper is removed.

Mark off where the "tabs" should be that connect to the bumper. You should NOT cut through this area when trimming off the rest of the grill. You trim the tabs to fit the bumper later after you finish cutting.

I taped off the area on the aero grill I DIDN'T want to cut. I clamped it in a vise-like device (like a Workmate bench) and used Roto-Zip cutter. Some use a Dremel. Same thing. I used the plaster board cutting bit and SLOWLY worked my way along the edge. You will need a "soft" file to remove any burrs that you get from the cutter melting the plastic.

Be sure to wear safety goggles as the plastic really gets flying as you cut!

Take your time. You may need to go back and make an extra cut here and there which is better than cutting all at once and finding out you cut too much off!

Good luck!
 
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Old Feb 8, 2008 | 07:09 PM
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ok so today i installed the bottom grill and i thought i try something different I left the top tabs on but cut off all the bottom tabs. Now the grill fits in but it isnt flushed all the way. The top and bottom corners and still sticking out also the whole bottom wont even get flushed because it feels like the center is making it bulge out. Did u cut the center peice to make it flushed? Anybody have any suggestions. I think i am just gonna pull it out again and cut off all the tabs and use 3m tape. Or do u think i should just get another bottom piece and leave the tabs. And the double side tape took for ever take come off. thanks
 

Last edited by djmini420; Feb 9, 2008 at 09:36 AM.
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Old Feb 12, 2008 | 01:45 PM
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Originally Posted by djmini420
ok so today i installed the bottom grill and i thought i try something different I left the top tabs on but cut off all the bottom tabs. Now the grill fits in but it isnt flushed all the way. The top and bottom corners and still sticking out also the whole bottom wont even get flushed because it feels like the center is making it bulge out. Did u cut the center peice to make it flushed? Anybody have any suggestions. I think i am just gonna pull it out again and cut off all the tabs and use 3m tape. Or do u think i should just get another bottom piece and leave the tabs. And the double side tape took for ever take come off. thanks
Not sure if cutting the tabs off is that good of an idea unless that 3M tape is REALLY sticky and can sustain winds at 120mph, or faster! That is why I suggested removing the bumper and marking off the tab areas and not cutting through them but just trimming them back to fit through the tab holes. You could just fasten it with the 3M tape, if you lose it then buy another one. Or just go buy the aero kit!

Good luck!
 
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