DIY Upper Grill Block - Toyota Nation Forum : Toyota Car and Truck Forums
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#1 Old 11-19-2011, 07:55 PM
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DIY Upper Grill Block

I took what LeanBurn did & tweaked it a little bit. I started a new thread so that people could search for this easier. I bought a $5 piece of foamboard. After cutting it to shape for the upper grill I covered it in black gloss vinyl since my wife had a piece that was big enough to cover it. I punched 2 holes through it & inserted a pin in each side with a cotter pin on the inside of the grill. Very simple to do. I bought many choices at Lowes as I was not sure of what would work. It looks very clean some I'm excited to see if it helps this winter.

Here is the sheet of foam board.


Here it is after I cut it out.


After the gloss black vinyl.


Assortment of fasteners I bought. I used the pins on the right side of the pic.


A few pics of the finished grill block. Now I just need a "S" to attach to the grill block.






I'm going to make one for the lower grill on my Prius too. I have to go to Seattle on Monday so I'll see how this works.

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#2 Old 11-19-2011, 08:36 PM
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Good job Jim.
I've been keeping an eye on the temp gauge. No diff. All seems normal.


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#3 Old 11-19-2011, 08:50 PM
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That looks nice!! but isn't blocking airflow to the engine bad for it?

Also can you take a pic from a further distance?

Last edited by c_huynh32; 11-19-2011 at 08:53 PM. Reason: spelling
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#4 Old 11-19-2011, 08:58 PM
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That looks nice!! but isn't blocking airflow to the engine bad for it?

Also can you take a pic from a further distance?
We're following LeanBurn's lead to try to get the engine up to temp faster. So far no diff in temp gauge reading.
If you see semi's on the H'way, they have a curtaim to cover the grill in winter.


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#5 Old 11-19-2011, 09:00 PM
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That looks nice!! but isn't blocking airflow to the engine bad for it?

Also can you take a pic from a further distance?
Not in cold weather areas. Many newer cars don't even have an upper grill. The lower grill provides more than enough air to keep the engine cool. Read the posts in the chat thread about it.

I can take a picture from farther away when I pull out of the garage. I can only get so far back in the garage.

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#6 Old 11-19-2011, 09:10 PM
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You don't have to worry about overheating the engine when it's cold... that's what the fans are for if needed.
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#7 Old 11-20-2011, 11:27 PM
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Looks tacky :/ I guess function>form.

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#8 Old 11-20-2011, 11:31 PM
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Looks tacky :/ I guess function>form.
I was trying to improve on the look from what LeanBurn did. I was more interested in seeing the difference on my trip to Seattle tomorrow. While driving nobody can see it & it's very easy to take on & off for trips. If it adds 2-4 mpg than it's worth it IMO.

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#9 Old 11-21-2011, 12:06 AM
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VERY nice! PLEASE post numbers for us when you get done with that trip!

I'll have to find a way to do it inside the grille when I get my Altis grille, GOTTA show that sucker off, lol


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#10 Old 11-21-2011, 09:54 PM
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VERY nice! PLEASE post numbers for us when you get done with that trip!

I'll have to find a way to do it inside the grille when I get my Altis grille, GOTTA show that sucker off, lol
I was thinking the same thing but this was a quick one so I could see benefits.

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#11 Old 11-21-2011, 10:12 PM
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So I went to Seattle & back today. Maybe not the ideal day as the weather was terrible. It was pouring rain almost the entire time up & back with a lot of water on I-5. I also had a slight tailwind on the way north but it picked up in the afternoon when coming home & I had a very strong headwind southbound. The outside temps were from 37F-48F & my coolant temp never moved above normal.

That being said the results of the grill block speaks for itself. I was traveling between 55-70 mph with a small amount of city driving getting to & from the Seattle office. I've had several times when my computed actual MPG was higher than my display & this was one of those times. I knew that I was getting great MPG as I traveled 343.6 miles & I was still above 1/4 of gas.

This was a sample of the conditions as I was headed southbound back to Portland.


This was my display average MPG which was pretty good anyway for the amount of rain & wind that I drove through.


This pic shows the trip meter as I stopped to fill-up.


Here is what it took to fill-up. I used the same station, pump & filled to 1 click after it stopped like I always do.


So the bottom line......
343.6 miles/8.745 gallons = 39.29 MPG

I've never come close to MPG in conditions like these. I would be happy with 32-34 MPG so this proved a great benefit. Now to design one for the inside.

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#12 Old 11-21-2011, 10:29 PM
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This will improve too when roads are dry and no puddles.


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#13 Old 11-21-2011, 10:39 PM
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This will improve too when roads are dry and no puddles.
That's for sure, it would have been several MPG higher with dry roads.

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#14 Old 11-21-2011, 11:04 PM
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very nice!! Cant wait to see your "hidden" design!!


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#15 Old 11-22-2011, 10:23 AM
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this would be an awesome mod! I commute about 130 miles daily (mainly highway) so this would be a real money saver!



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