Acura RSX Budget Mesh Front Grille (Gutter-Guard DIY)
Introduction
This guide covers building a blacked-out mesh front grille for the Acura RSX using aluminum gutter-guard sheet as the grille material, for roughly $15 CAD (about $7-9 USD) in parts. It replaces or fills the lower center bumper opening with a clean custom mesh and, unlike commercial kits, protects the air-conditioning condenser behind the opening from road debris. The method here is written for the 2005-2006 RSX, whose lower bumper carries a removable plastic insert that doubles as a cutting template; 2002-2004 cars have a fixed center section that must be cut out with a rotary tool, making the job harder. The same idea also works on the Integra. Expect a straightforward afternoon project with basic hand tools. Adapted from a community writeup by Hellie on Club RSX (https://www.clubrsx.com/threads/diy-05-custom-front-grill.317165/), including corrections from the follow-up discussion.
Reference
Tools Required
- Socket or ratchet set and screwdriver for bumper hardware
- Trim-clip / panel removal tool
- Permanent marker for tracing
- Tin snips or metal shears for cutting the mesh
- File or sandpaper to dress cut edges
- Gloves
- Rotary tool / Dremel (only for 2002-2004 cars)
Parts Required
-
Aluminum gutter-guard mesh sheet (about $7 for a 4-pack)
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Black caliper paint
-
Clear coat (optional, chip protection)
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Door-edge trim (optional, only for the no-removal method)
Safety Warnings
- ⚠ If the painted metal chips and bare metal is exposed, touch it up promptly; left alone, exposed metal can corrode.
- ⚠ Running the car with the lower opening completely uncovered exposes the A/C condenser to road debris. One owner reported a condenser failure within a year of highway driving with an open opening, so keep intact mesh in place to shield it.
- ⚠ Cut gutter-guard edges are sharp. Wear gloves when handling and dress the edges before installation.
Step-by-Step Instructions
1 Gather materials and confirm your car's opening type
Pick up a sheet of metal gutter-guard mesh (a 4-pack runs about $7 and yields enough for several grilles) plus black caliper paint; keep clear coat on hand if you want extra chip resistance. On the 2005-2006 RSX the lower bumper has a removable plastic center insert you can use as a template, which is what makes this easy. On 2002-2004 cars the center is molded in and has to be cut out with a rotary tool, so plan for a more involved job on those model years.
2 Remove the front bumper and center insert
Take the front bumper off; it is held by six screws and eight clips. With the bumper free, remove the plastic center insert, which is retained by two screws and two spring 'bowtie' clips. Freeing those spring clips without damaging them is the fussiest part of the whole job. If you also want the outer fog-cover panels out, push the two small L-tabs on the top and bottom inside edges and they pop loose.
3 Trace the mesh from the plastic template
Set the removed plastic insert on top of the gutter-guard sheet and outline it with a marker. Note that the mesh has a slight built-in arc: orient the sheet so that arc faces away from the direction you intend to bend it. Working with the curve this way forces the mesh to lie flat and sit flush against the bumper instead of bowing outward.
4 Cut the mesh with snap-in retention tabs
Keep the full factory height of the gutter-guard sheet and trim only about an inch or two off each side. Along the lower edge, cut long U-shaped tabs so they line up with the existing holes in the bumper structure; these tabs hook into those holes and lock the panel in place, which is what gives the finished grille its stability.
5 Test fit before painting
Offer the cut mesh up to the opening and confirm the bottom tabs seat into the bumper holes and the edges sit flush all around. Adjust the cuts now, while the metal is still bare and easy to rework, rather than after paint.
6 Paint both sides
Remove the mesh and coat both faces with the black caliper paint, then let it dry for a few minutes. For durability, follow with a clear coat; the paint is prone to chipping at the cut edges, and a clear layer helps it survive stone strikes.
7 Reinstall the mesh and lock the top edge
Set the painted mesh back into the opening. Fold the leftover inch or two of side material back toward the bumper to stiffen the panel and hide the raw edges for a cleaner look. The foam strip that rests on top of the plastic presses down on the upper edge of the mesh and holds it snugly in position.
8 Refit the bumper
Reinstall the front bumper with its six screws and eight clips, then step back and check the fit and alignment of the new grille from a few angles before calling it done.
Pro Tips
- 💡 No-removal alternative: measure the bumper opening, trim the gutter-guard about 1/8 inch undersize on every side, run door-edge trim around the perimeter as a cushion, and press the panel in from the front. It skips bumper removal but is not necessarily quicker.
- 💡 Do not waste time hand-cutting the two small outer fog openings to match; factory plastic covers look far cleaner, and one builder spent about 45 minutes on two side pieces and still preferred the stock plastic.
- 💡 Folding the trimmed side flanges back over the edge both stiffens the panel and conceals the sharp cut edges.
- 💡 The outer side covers pop off easily via their L-clips, but many owners feel the bumper looks unfinished with those openings left bare.
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