I looked for previous post dealing with this but couldn't find it.

I finally got my grille and surround installed. I gave rocspo's directions to the installer which were great and he made some changes.

1 Instead of cutting out old sensor mounts he made new ones. I measured the trapazoid opening and little wings and made a template on an index card which he used to cut grille mounts out of 3mm ABS sheet (found at local plastic supply) and drilled an 18mm hole in center. I would have rather used sensor mount brackets, but since I couldn't find them for that oblong sensor, he glued sensors directly to ABS. (Since then I found a BMW sensor mount that I think would have would have fit).

2 Instead of mounting sensors with connectors pointing inward, he pointed them outward in order to avoid having wiring exposed behind grille. He glued wires from sensors directly around trapezoids so they can not be seen, and they exit to the side of grille.

3 He then mounted wiring harness to run below grille, and then extended sensor wires to go below and around surround. Since sensor wires are not color coded, he colored them with different colored nail polish before he cut them. I thought the sensor wires looked to be about 24 gauge but couldn't find it locally and didn't have time to order it online (a company called NTE has it) so I found a couple old power supplys from a radio and an old router which I think is 24 gauge and he cut it up and spliced them in. They work!

As rocspo did, he removed styrofoam from behind original bumper, painted bumper behind grill and mounts flat black. He didn't glue mounts permanently until he calibrated them after reassembly.

Thanks to unhinged, rocspo, and ryan for all you help.

I have attached pictures which were taken in direct sunlight so the sensors look more noticeable. In regular light they are hardly noticeable.

 

In my opinion, that is how the front end is supposed to look. Nice, clean install. You must be thrilled.

Orkney

 

Perfect. I need to get launched on that project.

 

Great looking mod, nice work!

 

amazing... I need to get this done as well. Well done!

 

Looks good, but surprising not as dramatically better as I thought it would.

 

Really looks good. Your sensor install is clever.

 

Very nice!!!

 

Looks great, nice job!

 

I concur. I wish mine looked this way. Maybe someday ...

 

Great job! Great look.

 

Can you be a bit more specific as it relates to the sensor install portion of the project.

Maybe some close up pics of the templates you refer to with measurements.

A pic or drawing of uninstalled template.

Perhaps a list of materials needed

Some sketches of how they mount and the wires so I can print out your answer to hand to the mechanic.

I'm sure he can figure it out but why reinvent the wheel if you've got the blueprint.

Also curious as to the sensor aim test procedure. Did he mount in like a rubbery cement and reposition while the glue was still malleable? How did he accurately figure out the correct sensor trigger point?

It would be so helpful if you could compile a paragraph or two of a detailed project list to do this from start to finish so all the members that plan to do this mod can simply print it out and hand it to someone. Basically a how-to sticky with a pic or two.

Thanks in advance.

 

Fantastic! where did you buy the grill from?

 

I'll pm you with the secret decoder ring.

 

I like it, looks very clean nice job.

 

Shaun,Unhinged will hook you up.

 

Polarisnavyxj

I wish I could be more specific as to how everything was done but I only spoke to the manager and not the actual installer so I did not get specific details, just a general description.

I gave him the options of cutting out grille mounts and sensor mount bracket from old bumper as rocspo did, removing sensor mount bracket from old bumper (my mechanic said they can be removed with a heat gun) and attaching to fabricated grille mount, or glue sensors directly to fabricated grille mount.

He chose to glue them directly to the fabricated ABS mount and face connectors outward toward fender. He mounted wiring harness under grille (there is a lip below the grill that he tucked it into)and extended sensor wires to run around grille and up fender to sensors. From sensor he glued wires on back rim of trapazoids running to fender so no wires are showing anywhere.

As for materials:
He had ABS sheet- white to cut out grille mounts with template I provided. I think the thickness is 3mm (0.11811) He had glue for mounting and connectors for wire splicing.

I provide him with:
Template for grille mount.
8” and 4” black cable ties from OReilly Auto and cable tie adhesive mounts Shop Utilitech 10-Pack 1-in Nylon Cable Ties at Lowes.com
24 AWG (I think) double wire from 2 old power supplies (1 telephone, 1 router) The wire is about 1mm OD.
5pks of Raychem Heat shrink tubing from lowes to seal wires when spliced. I gave him 2 (1/8 to 1/16) and 2 (3/8 to 3/32) but I don't know which he used.
1 bottle red and I bottle white nail polish to code sensor wires before cutting. (Dollar Store)

I am attaching a picture of a template I just made on an index card. I didn’t cut it out so you can see measurements. I am also attaching the instructions I gave to installer (plagiarized from rocspo) which describes calibration process (see attached file below pictures).

Good Luck

 

much abliged!

 

All very helpful. THANK YOU!!!

 

Sometimes I feel like the only one who doesn't hate the bumper bar. It has never bothered me.