Shaved Mustache/ Crash Bar mod

[Kegsandeggs]

So i have seen a ton of people looking for this look, so i documented the whole thing. Even if you dont have a full machine shop like we had acsess to, simple hand tools can still make this work. Just a heads up, this is an extra crash bar ordered from my Chevy dealer, and is for OFF ROAD use only. That being said, Lets begin!



This is the ever elusive "Mustache" people are complaining about. Also that is a 1/2 showing CX racing interooler...more on that later

First I pulled off my bumper (Search forum for bumper removal) and removing the Crash bar (8 18 mil bolts next to the intercooler)





Than we torched the "legs" off and welded on 1/8's plate metal





and than cut a 1.5" tube and welded to the end plates.







Put bumper back on, hidden very nice (without grill on, still need to moddify that)





THAN take your lower grill and dremel off the tabs holding the mustache cover on the RS grill off and botta bing...Clean Shaven!!



NOW you could leave the lower grill off, for thoes who want a dented to hell intercooler or it get stolen right out of the bumper, skip the last step... Thanks guys!

 

[Bluegrass]

Great job- that looks awesome!

 

[River_Rat]

While the RS does not actually have the infamous mustache, this is nicely done.

 

[sx sonic]

Looks great, saw this on FB.

You're probably pretty good at pulling the bumper off now.

 

[Kegsandeggs]

While the RS does not actually have the infamous mustache, this is nicely done.

More done for the lower models... And ya, I've pulled my bumper off about 20 times this month

 

[SonicBoy24]

THAN take your lower grill and dremel off the tabs holding the mustache cover on the RS grill off and botta bing...Clean Shaven!!



NOW you could leave the lower grill off, for thoes who want a dented to hell intercooler or it get stolen right out of the bumper, skip the last step... Thanks guys!

Are you telling me that the only thing between me and a clean-shaven grille is a few tabs and the honeycomb continues underneath it?!
Spring can't come fast enough!!

 

[$ub$onic]

Are you telling me that the only thing between me and a clean-shaven grille is a few tabs and the honeycomb continues underneath it?!

Spring can't come fast enough!!

On a non rs sonic I don't think the honeycomb is under the stash

 

[Beastlick]

Are you telling me that the only thing between me and a clean-shaven grille is a few tabs and the honeycomb continues underneath it?!
Spring can't come fast enough!!

The tabs he mention are holding the foam pad over the steel bumper. OP did this mod on his RS = no stash but the honeycomb isn't open where a non RS has a big fat ugly smelly flat mustache.

On a non rs sonic I don't think the honeycomb is under the stash

nope, its evenly shelled out to fit that foam pad. I had to remove this pad with my billet style grille.

Kegs, looks great showing off that new IC!

 

[Kegsandeggs]

Are you telling me that the only thing between me and a clean-shaven grille is a few tabs and the honeycomb continues underneath it?!
Spring can't come fast enough!!

Hey, the lower level models have a plastic PC and a honey comb grill stuck... On the RS grill, there is a flat plastic piece on the back of the grill you can dremal tabs off, take a look at the first pic, and the last pic.

 

[SuperSonicRS]

On the RS grill, there is a flat plastic piece on the back of the grill you can dremal tabs off, take a look at the first pic, and the last pic.

If you remove these plastic pieces, are you able to see the factory crash bar behind it?

 

[SonicBoy24]

The tabs he mention are holding the foam pad over the steel bumper. OP did this mod on his RS = no stash but the honeycomb isn't open where a non RS has a big fat ugly smelly flat mustache.



nope, its evenly shelled out to fit that foam pad. I had to remove this pad with my billet style grille.

Kegs, looks great showing off that new IC!

I'm kind of confused.
For those of us with non-RS 2012s, what happens when we try to take of the stache, do we have honeycomb or no?

 

[sx sonic]

I'm kind of confused.
For those of us with non-RS 2012s, what happens when we try to take of the stache, do we have honeycomb or no?

The stash on a non-RS is smooth. On the RS the grill is a full honeycomb. The upper half is just filled in so you can't see the crash bar. Kegan just cut out the upper part so the honeycomb had holes in it.

 

[SonicBoy24]

The stash on a non-RS is smooth. On the RS the grill is a full honeycomb. The upper half is just filled in so you can't see the crash bar. Kegan just cut out the upper part so the honeycomb had holes in it.

Thank you very much. I'll be removing the stache then.
:banana::banana::banana::banana::banana::banana:
:banana::banana::banana::banana::banana::banana:
:banana::banana::banana::banana::banana::banana:

 

[Blue hedgehog]

Thank you very much. I'll be removing the stache then.
:banana::banana::banana::banana::banana::banana:
:banana::banana::banana::banana::banana::banana:
:banana::banana::banana::banana::banana::banana:

Removing the stash isn't that easy for non RS owners. The RS has a totally different lower grill. Even if you went out and got a RS lower grill you would have to modify it to fit your non RS bumper. After you did all that and opened up the honeycomb you would be able to see the crash bar through the grill. To avoid seeing the crash bar you would have to remove it and build a replacement crash bar (this requires metal cutting tools a welder and materials) like the OP did. It sounds like a major undertaking for a RS owner withou the proper tools and skills. It's an even larger job for a non RS owner.

OP great work. And nice write up.

 

[SonicBoy24]

Removing the stash isn't that easy for non RS owners. The RS has a totally different lower grill. Even if you went out and got a RS lower grill you would have to modify it to fit your non RS bumper. After you did all that and opened up the honeycomb you would be able to see the crash bar through the grill. To avoid seeing the crash bar you would have to remove it and build a replacement crash bar (this requires metal cutting tools a welder and materials) like the OP did. It sounds like a major undertaking for a RS owner withou the proper tools and skills. It's an even larger job for a non RS owner.

OP great work. And nice write up.

I've got the tools and the time.
Plus, the crash bar can be repainted/removed/disguised.

Also, I won't necessarily be dremmeling out the honeycomb, all I want is to get that nasty-stache out of there.

I'm not worried, thanks though.

 

[Blue hedgehog]

I've got the tools and the time.
Plus, the crash bar can be repainted/removed/disguised.

Also, I won't necessarily be dremmeling out the honeycomb, all I want is to get that nasty-stache out of there.

I'm not worried, thanks though.

I'm not sure you understand. There is no honeycomb under the stash on a non RS grill. If you cut off the stash (the stash and honeycomb are all 1 piece) you will have a big whole where the stash was.

Just take a good look before you start cutting. I wouldn't want you to cut and find out it won't work.

If you somehow figure out how to eliminate the stash withou buying an aftermarket grill or modifying an RS grill. Post up a how to. I'm sure other members would love to know how. As far as I know Beastlick is the only one who has done it.

 

[Kegsandeggs]

The rs lower grill doesn't fit in the non rs? I thought the only difference was that the fog light wholes were cut differently? My next mod is front brake dust vents in the fog grills

 

[SouthFLSonic]

The rs lower grill doesn't fit in the non rs? I thought the only difference was that the fog light wholes were cut differently? My next mod is front brake dust vents in the fog grills

Nope completely different and anyone trying to do your mod on a nonRS will fail. They can remove and relocate the crash bar just the same but then need to make a new grille, buy a new grille, or try to make the RS grille fit with a lot of work.

You did a great job but it is only pertinent to RS owners and not the majority of owners here.

 

[ras42tbss]

Very nice job. Willing to give up some specs on that intercooler? Curious as to what the dimensions are...

EDIT: Nevermind, just saw your install post on the IC and googled it... Very nice mod though

 

[Kegsandeggs]

Very nice job. Willing to give up some specs on that intercooler? Curious as to what the dimensions are...

EDIT: Nevermind, just saw your install post on the IC and googled it... Very nice mod though

intercooler has been a nightmare being an RS owner, had to do a bit off fog light cutting... but it is scheduled for a final tune tomorrow, i will for sure post results