Pic 1 The curves at either end of the grille had to be constructed from something. TPO isn't exactly an 'off the shelf' item. I decided to go with PVC. For one thing it is
readily avilable and it's a thermoplastic. Figured it should (hopfully) work. It can be heated and molded so I made a wooden form. I had planned to make the full female form also but I
broke the blade on my scroll saw and only got the two made. Made it work. Pic 2 I just put the section of PVC over the male form and heated it with a heat gun. When soft, I pushed the two female forms over it to force it onto the male form. I
then sat a gallon bucket of paint to weight it down and let it cool. Worked fine.
Note: PVC when heated gives off fumes that can be harmful. Only do this in a well ventilated area.
Bottom view of curved bit
Pic 3
Pic 4
Pic 3 Curved plastic piece bonded into the bumper. Pic 4 Gap between the Gredy lip and the plastic pice will have to be filled with scrap. The Greddy fits on at an angle there so I couldn't make a simple join.
Top view of curved bit
Pic 5
Pic 6
Pic 6 There is a large gap between where the stock bumper ends and the curved piece of plastic. Pic 7 This will be filled with a scrap of plastic from the PVC pipe I used.
