Full replacement mustacheless grill

[Beastlick]

For those of you who know the months of work I put into the billet style mustacheless grille, the prototype turned out great. Its still on my car and holding up very well.

With that said, its been bothering me that I didn't design the components in a very cost effective way. To the dozens of messages I've received over the past year, it still seems there is a need for a clean replacement grill without that silly mustache.

I spent the weekend mocking up the trim profile and reverse engineering the mounting tabs. Within the coming weeks, I will have a first set laser cut and plastic-welded together.

Now I have a question for anyone who might be interested in a set. Would you rather have a full replacement including trim or would you rather keep the "chrome" trim and swap out the old black honeycomb for a new design w/o mustache (designs still in progress). Poll added to top of thread.

As of right now this only pertains to non-RS Sonics. If all goes well, i'll purchase an RS grill and make them available too.

Couple of quick pics over the weekend....




Added 3/23/15:
Here are the individual samples with the % of airflow provided.

Diamond XXL, 70% open

Stacking Oval, 70% open

Diamond XXL Flat, 60% open

Hexagon XXL, 60% open

Small Hexagon, 60% open

Oval Zig-Zag, 50% open

Small Diamond, 60% open

Diamond Extreme, 35% open

Hex Perf, 77% open

Slotted Perf, 50% open

Perf XXL, 40% open

Small Perf, 40% open

1/4" Woven, 70% open

Single Weave mesh 80% open

Double Weave mesh 65% open

 

[bchs89]

Excellent work sir. Personally, I like the OEM chrome surround for the stock grill. The mustache delete has been long overdue.

 

[rdss]

Your skill and attention to detail still amazes me, if I still had my sonic I would prefer a custom surround to keep the stock one in one piece for later reinstall or sale.

 

[cndctrdj]

I like the chrome trim. Have any designs in mind?

 

[Scot]

I'd say to go with whatever is easiest to produce - IMO, I can change my chrome trim to any color with vinyl / dip - or take it out alltogether.

If you could, make it for about $5.

 

[Beastlick]

I like the chrome trim. Have any designs in mind?

I'd say to go with whatever is easiest to produce - IMO, I can change my chrome trim to any color with vinyl / dip - or take it out alltogether.

If you could, make it for about $5.

$5 would be a pair price

Its kind of a toss up to produce. Keeping the chrome would be harder to produce the mounting clip portion but creating a completely new trim, I can control the shape and not have to design around an "existing part" or attachment method.

No specific designs as of yet. Figuring out how to produce sets of mounting clips without tooling to keep the cost down was my first priority. For the prototype, it will more than likely be a staggered hole pattern of some sort. Further designs will only compliment any Sonic.

 

[Black Turbo LTZ]

I'm in for the whole new design without the stock trim since it cuts down on cost and I can swap one for the other without taking things apart. I'm in for buying one as soon as your ready for production/sale

 

[$ub$onic]

1-2-3 blocks. Million and one uses .


Also in for results!

Gotta love laser cutting. Keeps me having a job!

 

[ripper1]

What ever is the cheapest

 

[Blue hedgehog]

What ever is the cheapest

A saws all and chicken wire would be the cheapest. But I doubt Beastlick would put his name on it.

 

[Beastlick]

1-2-3 blocks. Million and one uses .


Also in for results!

Gotta love laser cutting. Keeps me having a job!

2-4-6 blocks worked great!

Making a Chevy Sonic cookie cutter grill hasn't been easy. Laser cutting adds metal as possibility as well.

 

[$ub$onic]

2-4-6 blocks worked great!



Making a Chevy Sonic cookie cutter grill hasn't been easy. Laser cutting adds metal as possibility as well.

The big ones!

It's scary how fast a cutting laser can cut metal. We make a lot of the oem optics that go into the higher end ones.

 

[Beastlick]

Update: I had an initial set of cookie cutter tabs machined and solvent bonded the snaps, will be finishing up the mounting over the weekend and onto the visual elements of this grille.

 

[Inferno]

I love the RBP grill designs. I like the more agressive style!

 

[static54]

Want to use mine as a demo?

 

[Scot]

Update

Needs moar update!!!!

 

[Beastlick]

I was able to test out the clips early this week. There are some minor changes that needed to be made. Should have another set to test out by next week. Sorry for those wanting pretty pictures of the visual area but the mounting was the issue in bringing my first prototype to life, hard to produce volume runs.

I will be doing some sketching over the weekend of the visual area to get concepts going. If anyone wants to help or influence some designs, I do have plain outlines you could print out and draw on. PM me if you're interested.

 

[gijoefontaine]

MIND BLOWN!

cant wait to see how this turns out. what's your predicted cost if you are in fact going to start selling them?

 

[Beastlick]

I'm hoping to keep the cost around 300 depending on complexity. Got my updated set of tabs machined. Should be able to get them on this weekend. We're getting very close to release. I also have a couple members helping with the visual designs.

 

[Beastlick]

Freshly shaved stock.....

This was just a quick visual pattern to see a more complete product. The custom designs will be wrapped up later this week. Should have 3-5 options to choose from for this first round.

I'm pretty sure I will be filling in the area where the mustache normally is but behind the design similar to how the RS grill is.

Question: Is mounting a license plate an option wanted?