[Theo]

I originally posted this on NAM, but I thought folks on MINI2 who were contemplating the installation of Aero Grilles might benefit from my efforts.

I finished installing Koopah's new Aero Grilles in the stock MCS bumper. It went about as I had expected: upper grille easy...lower grille a PITA but doable. BTW, don't even attempt the lower grille if you (a) are *not* the @nal-retentive type who actually enjoys plodding throught painstakingly detailed tasks and (b) don't own a Dremmel tool!

After reading SamJ's instructions and contributors' notes which I found HERE , here's what I did differently from the write-up when installing the lower grille:

(1) I made a template of the lower Aero Grille by pressing the grille into a strip of cardboard. I outlined the grille on the cardboard with pencil. Removing the grille, I then drew "notches" where the cardboard had been punched by the tabs. The outline and notches were cut out of the cardboard and the whole thing was taped to the lower grille area of the bumper. I then marked the new slot locations on the bumper using the notches on the cardboard. This worked really well.

(2) After cutting an unnatural amount of plastic off the lower grille edge, I still ran into trouble making both the top and bottom edge fit flush with the height of the bumper surface. A little investigation showed that the grille was riding on the protruding "louvers" to which the old body colored grille slat was attached. After sizing things up, I took the bold move and cut the louvers off. This created a half inch opening behind the grille and was not noticeable once the grille was attached. The new openings should also marginally increase airflow to the radiator. Now the lower grille was flush with the bumper surface. This, also, worked really well.

(3) I debated on how to "black-out" the remaining yellow bumper material: tape, paint, permanent marker...? I then realized that the bumper material is black so I decided to try a fuzzy sanding wheel I have for the Dremmel tool and remove the paint. Well, here's the deal...it *does* take the paint off quite well, but it doing so, the surface heated up enough to allow a slight amount of yellow pigment to be bonded into the melted plastic. It looked ok, but it did not work out *really* well. However. the plastic was almost black so I put two coats of high temp flat black paint on it.

(4) The only part of the installation that made me think a while was the gluing of the grille to the bumper. I really wasn't sure if I wanted to glue it. What if someone taps me and I need to replace the lower grille? Will I need a whole new bumper? I have tried to break-loose plastic that has been epoxied and it is pretty much impossible. So I got an idea.

The four end tabs (2 on each corner) protrude into the bumper shell quite far. Firmly fastening these four tabs would hold the lower grille quite securely in place (remember, I drilled slots for all the tabs on the lower grille which gives added support). So I fashioned four rectangular rubber-backed plastic "washers" with slots in them and drilled a 7/64 hole through each of the four tabs. The rectangular washers were pushed on the tabs and all four tabs were secured with brass cotter-pins going through the holes drilled in them. The grille is now quite frimly attached. This will allow me to remove the lower grille should it ever need replacing. This worked really well.

So, that's it. Below are some pix of the finished product. I really like the contrast of the black Aero Grilles on the Liquid Yellow body, though I'm sure it's not to everyone's taste.

Hope this helps,

Theo