The definitive Discovery 4 grille mod..."How to.."
This topic is to show you how to turn one of these
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Or these
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Depending on what you buy into one of these
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Or if you like black
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You will need lots of clamps
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My intention is to copy a cutting guide into my gallery that can be printed out and used, I cut up and used the D4grille outer as a template
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update
CUTTING THE D3 DONOR GRILLE
You need to remove the centre spar and the upper spar as far as the rolled edge for the bonnet to result in two pieces below
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The cut lines for the side cuts are in red in picture 1
The cut line for the upper spar is in pen on the masking tape in picture 2
Picture 3 shows the diagonal cut you need to make on the underside of the middle spar, this is best done from the back of the grille, you need to keep the mounting points for the grille
Picture 4 are the links between the middle and lower spar, these need to be removed inline with the back of the lower spar
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Make the simple cuts with a Dremel if you have one, then complete them with a standard hacksaw blade
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Here's the cut on the links to the lower spar
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Once you've removed the centre section take some time to clean up the cuts, this makes the marking out for the next cuts easier
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On the inside of the top rail, these strengthening ribs need to be sanded down
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Now you need to mark out to fit the D4 insert, the sides need trimming down
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Here's the plastic template I made using the D4 insert as a guide
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On the lower spar you need to mark the centre line, this is to aid setting out the 4 cut outs for the legs of the insert.
At the back of the lower spar inline with the grille mount the centre is 404mm
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At the front it's 410mm (make sure as you mark the line, your pen doesn't slip )
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Now you need to mark a line across the lower spar 55mm from the rolled edge at the front, this marks the depth for the 4 cut outs
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Line up the template on the centre lines and the 55mm line and mark the cut outs
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Take your time cutting these out, they will be visible on the finished grille
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I use this type of cutter in the Dremel
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Once cut, remove a little material on the underside of the spar to aid the fitting of the insert
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You should have this when you've finished
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CUTTING THE D4 INSERT
This is quite straight forward, you need to keep as much of the two spars as possible, and trim the feet down on the legs
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This is what should remain on the insert
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GLUEING UP
Test fit the insert dry and trim / fettle where required
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From the D4 insert, trim 2 packers
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Glue these on the inside of the donor to aid glueing the insert in, then let the tiger seal cure before proceeding
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Run a bead of sealant on the packers to bond the insert to, and around each cut out on the lower spar to bond the legs in
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Centre the insert and clamp up, let the sealant set up overnight, then remove the clamps and add more sealant where needed to bond the insert in along the top of be D4 insert and around and under the spars
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The finished product
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Admin note: this post has had its images recovered from a money grabbing photo hosting site and reinstated Altox GSM FBH controller thread
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
Last edited by beanie on 8th Sep 2013 6:44 pm. Edited 13 times in total
6th Aug 2013 9:19 pm
Narpy
Member Since: 18 Jul 2011
Location: Stockport
Posts: 7830
Ooooo a D3 to D4 grill mod thread with piccies.
This could prove popular. Mods:
Front Fogs + Halos
FBH Remote Control
The 1st Ever RRS Modded Grill
Garmin Nuvi + D4 Surround + Reversing Camera.
D4 Steering Wheel.
Rear Boot Spoiler.
Twin Brake Lights.
Wing Mirror Indicator Repeaters.
Long Roof Rails
Make your own Narpy grill thread
I'm not scared, I'm outta here.
I plan to make a silver with black insert this weekend, the contrast of colours should make good material for this topic Altox GSM FBH controller thread
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
2nd Sep 2013 7:40 pm
Simonstarski
Member Since: 24 Jun 2012
Location: Cornwall
Posts: 686
Beanie they're very 8)
Did you ever get a "how to" together on the process. As much as I like my Narpy grill I've a spare silver one in the shed. You know, in case I totally up the cutting when I did my mods.
There's no chance I'll ever go back to a standard D3 grill now so wouldn't mind a D3.5 with black inserts.
Dare I say its smarter than a Narpy now that going to open a can of worms Narpy Grill, tinted windows, Smooth leather wheel (TLO Group buy), ACM fitted (thanks TLO), Rear door loom and Row 2 & 3 audio switch upgrade, RRS 20" wheel change, 285 Cooper LTZ's Sat Nav Mod (until I get a Faultmate upgrade), Front & Rear lamp guards. 4x4 screen now switched on - Woody32, Follow me home reverse lights - woody32, Auto release EPB - Woody32. Off Road Navigation - Woody32. Remap + EGR's switched off. Full chassis clean and Waxoyl.
2nd Sep 2013 9:47 pm
Narpy
Member Since: 18 Jul 2011
Location: Stockport
Posts: 7830
Oh don't say that Si, his head'll swell up and he's not even done the How-To yet. Mods:
Front Fogs + Halos
FBH Remote Control
The 1st Ever RRS Modded Grill
Garmin Nuvi + D4 Surround + Reversing Camera.
D4 Steering Wheel.
Rear Boot Spoiler.
Twin Brake Lights.
Wing Mirror Indicator Repeaters.
Long Roof Rails
Make your own Narpy grill thread
I'm not scared, I'm outta here.
2nd Sep 2013 9:56 pm
Simonstarski
Member Since: 24 Jun 2012
Location: Cornwall
Posts: 686
Ill never forget the cramp I had in my hand the evening after following your how to, using a hacksaw blade without a handle. i was agony after an hour or two still its turned out very swish indeed.
Now I need to escape to the shed to cut my spare standard one up. Especially now that x-factor thing is back
It's been ages since I've hacked a grill to pieces, this "how to" is over dew Narpy Grill, tinted windows, Smooth leather wheel (TLO Group buy), ACM fitted (thanks TLO), Rear door loom and Row 2 & 3 audio switch upgrade, RRS 20" wheel change, 285 Cooper LTZ's Sat Nav Mod (until I get a Faultmate upgrade), Front & Rear lamp guards. 4x4 screen now switched on - Woody32, Follow me home reverse lights - woody32, Auto release EPB - Woody32. Off Road Navigation - Woody32. Remap + EGR's switched off. Full chassis clean and Waxoyl.
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
2nd Sep 2013 10:13 pm
Narpy
Member Since: 18 Jul 2011
Location: Stockport
Posts: 7830
Over due..................you're not wrong there.
By the time he's written the damn thing, we'll all have bought D4's anyway. Mods:
Front Fogs + Halos
FBH Remote Control
The 1st Ever RRS Modded Grill
Garmin Nuvi + D4 Surround + Reversing Camera.
D4 Steering Wheel.
Rear Boot Spoiler.
Twin Brake Lights.
Wing Mirror Indicator Repeaters.
Long Roof Rails
Make your own Narpy grill thread
I'm not scared, I'm outta here.
Last edited by Narpy on 2nd Sep 2013 10:38 pm. Edited 1 time in total
2nd Sep 2013 10:14 pm
Simonstarski
Member Since: 24 Jun 2012
Location: Cornwall
Posts: 686
I best make some space and recharge my dremmel then Narpy Grill, tinted windows, Smooth leather wheel (TLO Group buy), ACM fitted (thanks TLO), Rear door loom and Row 2 & 3 audio switch upgrade, RRS 20" wheel change, 285 Cooper LTZ's Sat Nav Mod (until I get a Faultmate upgrade), Front & Rear lamp guards. 4x4 screen now switched on - Woody32, Follow me home reverse lights - woody32, Auto release EPB - Woody32. Off Road Navigation - Woody32. Remap + EGR's switched off. Full chassis clean and Waxoyl.
I best make some space and recharge my dremmel then
Starter for 10 Si, remove the centre grille spar as for a RRS, but do not create the "chamfered triangles" to fit the RRS grille , you can cut these off inline with the lower spar & do not cut any more grille away at the sides Altox GSM FBH controller thread
IID Pro MV License - D3, D4 & RRS - Enabling, Updates, D4 & RRS Timed / Remote Climate, D4 Bluetooth fitting
PM me for details
Owner of the original "Beanie" grille
D4 & RRS style D3 grilles made to order
2nd Sep 2013 10:25 pm
Simonstarski
Member Since: 24 Jun 2012
Location: Cornwall
Posts: 686
this is already sounding easier on my hands Narpy Grill, tinted windows, Smooth leather wheel (TLO Group buy), ACM fitted (thanks TLO), Rear door loom and Row 2 & 3 audio switch upgrade, RRS 20" wheel change, 285 Cooper LTZ's Sat Nav Mod (until I get a Faultmate upgrade), Front & Rear lamp guards. 4x4 screen now switched on - Woody32, Follow me home reverse lights - woody32, Auto release EPB - Woody32. Off Road Navigation - Woody32. Remap + EGR's switched off. Full chassis clean and Waxoyl.
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)
up the cutting when I did my mods.
still its turned out very swish indeed.
