The grill that i started out with was a junkyard find. but original nonetheless. i first got the pieces i needed from ebodycrazy4ever
which so kindly cut XL as i ended up needing more then i thought. i trimmed the pieces and the damage so they were compatible. The "Glue" i used was a product called plast-ex which comes in 2 parts, powder and liquid. i used packing tape on the front side and stuck the pieces together, then i would fill the void with the powder and next add the liquid.once hard i would remove the tape and shape the area back to original. i found it worked well, it just takes practice.
i used the plastex as a filler as much as i could but it is hard to sand so when i got it fairly good i used a little bit of finishing puty to fill small imperfections.to prep i sanded the whole thing down until i could not feel any texture from the old paint.
the problems: