Since this is a daily driver and not something I'm showing off at all, I decided not to get picky about the grill appearance. If it bugs me I'll build it up with J-B Weld or some other filler then smooth and repaint, but it's just not noticeable from 10 feet away. When I hacked the crossbar out, I stayed about 1/16" away from the surround which I kept so as not to ding it with the hacksaw blade, then used a file and finally some 1200 grit paper to flatten and smooth it out.

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Happy Driving,
Kirk