I posted these pics in another thread, but I wanted to post them again for those who didn't see that thread.

I did the aero grill mod without taking off the bumper - the old grill pried out using my fingers, starting at the center and working out.

Then I used the dremel to cut out the existing louvers so the new lower grill could sit more flush. I followed the examples on the motoring file pdf to cut the lower grill, and after using the dremel to make new holes for the aero's tabs, it popped right in. I didn't use any adhesive or tape, and the lower grill is very secure. Its not quite as flush as some of the samples here, but Its flush enough for me -

 

Very nice, looks great. How long to it take you to do it?

 

Very clean look

 

Thanks!

It took about a half hour to do the top grill. Last night I did all the dremel work on the lower part of the bumper, and then painted the area behind the grill flat black. I let the paint dry overnight, then this morning I dremeled the lower grill itself, and popped it on. Not including drying time it was around 3hrs total. It would have taken a bit longer if I removed the bumper obviously, but I think this route worked out perfectly for me.

 

im doing this tonight...any tips or things to look out for?

 

I would follow the PDF file from motoring file - make certain that you use the chrome piece from the stock grill as a template for trimming the end of the lower aero grill - it will be much more flush.

I also mistakenly cut the support at the very center of the lower grill opening, instead of making a new slot for the center tabs on the aero grill. It didn't seem to matter much.

There will be LOTS of plastic debris from the dremel - it cleans up pretty well though. You can reduce this a bit by not staying in one place too long with the dremel. Use a steady hand, but let the dremel do the work, and try not to angle (or steer) the tool too much. I found that by following a straight line it was much easier to cut, and didn't throw as much crap all over. My dremel only has 2 speeds (15k and 35k), and it might be easier if you had one that was variable.

I used a drill bit (as opposed to a cutting wheel) on the dremel to make the new slots for the tabs on the aero grill in the bumper - I held the aero grill up to the car and drilled a hole at the center of each tab (where the tab contacted the bumber when the entire aero grill is centered), then used the drill bit to plow through the plastic to make the slot.

Also, make sure you have a very steady vise to hold the grill while you trim it. I used a microfiber cloth around the part of the lower aero grill that was in the vise to protect it and tightened it snug, but not too tight. Keep in mind that you can mount it and then take it off if you have to make some adjustments.

 

OK, so you proved it could be done, but I'd wager it would take *less* time with the bumper removed. Still, you did it. From my experience the grille this way sits out at least 1/4in from the bumper.

cheers,

 

If I had removed the bumper I could have probably had it a bit more flush, but for some reason removing the bumper scared the hell out of me. I know its not that hard to do, but I couldn't bring myself to do it.

 

That grill looks so sharp, it ought to be standard equipment on all MINIs.

 

My thoughts exactly! A no cost option! Even for an extra $300 I might even do it. Imagine the time saved if you could just check a box instead of going through all of this BS. Not that I didn't have fun doing it.

 

how does it fit more flush if you take the bumper off?

 

Someday, some smarties like Mini Mania will come out with an aftermarket lower grille that fits the standard bumper without any modification or dremeling! They will make a fortune! Hint Hint! You reading this, Ken?

 

Now that I've thought about it, and all the little pieces of abs plastic are out of my garage, I don't see how taking the bumper off has anything to do with how flush the grill is either. The only reason I've seen to remove the bumper has to do with working on the bumper with the dremel at a more reasonable height.

How you trim the lower grill itself has the most affect on how flush it is when mounted. The more you take off of it, the more flush it will be. I didn't mind sitting on the floor of the garage, so taking off the bumper didn't seem necessary. I could have probably made it a bit more flush, but I'm completely happy with the way it turned out.

 

V70R-

I must say, brilliant job!

I also must tell you that the bumper removal is far easier than the great job you did on the dremeling. It's literally just some screws. No brain surgery at all. But what you've done is demonsrated a successful alternate method.

Great Job.

 

I did mine without bumper removal also. I wasn't afraid to remove it, I just didn't see any reason to. I did just the way V70R described.