Here are the instructions on how I made my wire mesh grille. I did not create these instructions. They were given to me by alphaq2nu2aol and he deserves full credit for it. I just touched it up with some notes of my own.

Usual disclaimer: Neither I nor the originator of these instructions bear any responsibility for any mishap to your person, car or anything else during the course of following these instructions or during the use of the product of these instructions. In short, try it at your own risk! You're on your own.

• 1 stock Golf grille/fascia assembly
• 1 door edge trim kit, the slide-in type (black or clear works best)
• 1 piece aluminum gutter guard (3' length), the stiffer the better
• 1 poster board (36"x12" is enough) for the template
• 1 pair scissors
• 1 pair tin snips
• 1 can glossy clear coat spray
• 1 can glossy paint of your choice (optional)
• 1 roll 3M double-sided molding tape [black tape with red backing]
• 1 Phillips head screwdriver
• 1 flat head screwdriver
• 1 black marker (Sharpies work best)

1. Remove the grille/fascia from the car. Remove the screws across the top edge of the cross member. Be careful not to break the tabs after removing the screws. Along the bottom, there are 5 tabs. These tabs are not immediately obvious. The tabs which are further out are the tabs which hold the metal front fascia piece to the plastic frame behind it. The tabs you want to release are further back from these. You may have to look for them. Press up on the tabs using the flat head screwdriver. The grille should come out relatively easily.
2. Disassemble the grille/fascia. Pull the VW emblem from the front. There are 3 tabs holding it in place. Next remove the grille slats. There are 2 tabs on the back of each slat holding them to the plastic frame. Pinch the tabs together to release the slats. You will also need to cut the two plastic supports sticking out the front of the plastic frame after you remove the slats.

Remove the metal fascia from the plastic frame. There are metal tabs holding the fascia to the plastic frame. Bend the metal tabs up slightly to release the fascia. Once the fascia is disassembled, thoroughly wash and dry each piece. Store the slats in a safe place (it costs $70 unpainted from VW).

3. Create a template. Using the plastic frame as a guide, trace the basic shape the mesh will take on the poster board. Be sure to leave a 1" strip of excess along the bottom and top edges of the template. Rather than drawing a circle for the emblem, draw an upside-down "U" that will allow clearance for the plastic frame. Cut out the template and test fit it onto the plastic frame. You will need to trim away at the edges to get a clean fit. Also, be sure to leave a 1/4" space from the edge of the template along the curved sides around the headlights and center emblem for allowance of the door trimming.
4. Cut out the mesh. Once you are satisfied with the template, trace around the template on the mesh. Remember that there should be 1" of excess along the top and bottom of the template for mounting. Cut out the shape using the tin snips. Test fit and trim as necessary. Fold the 1" excess along the bottom forward and contour the mesh to the shape of the back side of the metal fascia. The excess along the top simply folds over the top edge of the plastic frame.
5. Paint the mesh. If you want to paint the mesh a different color, now would be the time to do it. Any high gloss finish paint will do. Paint the mesh and let it dry. Apply several coats of clear to protect the color. If you want to keep that aluminum look, just use the clear coat. This will prevent the aluminum from oxidizing.
6. Assemble the new grille/fascia. Once the paint has dried, attach the door trim along the cut edges of the mesh (around headlights and emblem). Now apply the double-sided molding tape to the back of the metal fascia where the mesh will come into contact with it. You may need to trim the mesh a bit if it doesn't clear the plastic frame. Next, snap the plastic frame into place and bend the metal tabs back to make sure it does not pop out. Apply more molding tape to the back of the plastic frame along the top edge. Fold the excess mesh over the top of the frame and secure it using the double-sided tape on the back. Next, snap the VW emblem into place.
7. Attach the grille/fascia to the car. Snap the tabs along the bottom first. Then snap the ones along the top and reattach the screws. The screws pull the tabs upwards securing it against the car. Do not tighten the top screws too much or you may break one of the tabs along the top of the grille.
8. Enjoy! Take lots of pictures and show everyone your work!

eliewnkhw

98 Black GTI VR6