Lower grille reinforcement for A/C condenser protection

galaxee · 09-20-2007, 11:21 PM

we've been meaning to do this for over a year- today we got some screening put in the lower grill to protect the a/c condenser from flying rocks and such. because we make a number of long road trips and with our luck, we're best off doing all we can to protect ourselves against loss...

carefully dropped the front bumper...

lower grille removed. see how anything that makes it through that grille whacks the a/c condenser? ick! (recall the bumper is dropped, there's far more exposed normally.)

we used some coated window-screen stuff and zip ties that have been waiting all year. DH melted holes for the zip ties with a very hot screwdriver. (the tricks you learn!)

back side of grille:

front side of grille:

i'll have to post pics of the grille installed when it gets light out. we kinda got rained on (go figure, it's happened about twice this summer) and then it got dark out.

eta:
final result

ACORNBLUES · 09-21-2007, 02:13 AM

galaxee - i thought you have a car bra? Or maybe the one you have does not have a screen ... I have a lebra one and it has a screen over both the top and bottom grill. good tip though.

patsparks · 09-21-2007, 04:00 AM

It is a good tip and will stop bugs in those bug prone places.

galaxee · 09-21-2007, 03:51 PM

the bra on our car doesn't have a screen on it, no. seems like a logical idea, eh?

we weren't quite so concerned about bugs, i mean yeah there were far more bug impacts in the lower condenser than in the upper area, but our main concern is rocks that could punch a hole in it.

apriusfan · 09-22-2007, 02:45 PM

<div class='quotetop'>QUOTE(galaxee @ Sep 21 2007, 12:51 PM) [snapback]515911[/snapback]</div>

Quote:

we weren't quite so concerned about bugs, i mean yeah there were far more bug impacts in the lower condenser than in the upper area, but our main concern is rocks that could punch a hole in it.[/b]

Bugs (if there are enough of them) can cut the efficiency of the heat exchange in the condenser. Lowered condenser efficiency will ultimately result in reduced mileage on hot days, so if you can protect the condenser, it is a good thing.

In addition to rocks, in the S.F. Bay Area, we get all manner of road debris (things like pieces of tire tread carcasses come to mind), so rock/debris protection is a very god idea (kind of like an ounce of prevention vs. a pound of cure)....

Where is the screen zip-tied to the lower grill? I was thinking about doing a screen mod to the lower grill myself. Where did you get the coated wire mesh? I tried Orchard Supply, but didn't like what they had (more like screening for windows). What you used looks a bit more substantial (presumably for the protection from rocks).

Great idea.

galaxee · 09-22-2007, 05:08 PM

DH punched holes in that lower grille in 3 places on the top and bottom (left, center, right) with a torched screwdriver. see the 3rd pic from the top, you can tell it's shaped like a screwdriver

i actually got the mesh from some leftover supplies from a non-science project from our lab last halloween. nobody needed it after we were done, so i took it home. i'm not quite sure what it is, but it reminds me of cat-claw proof window screening except stronger. it's pretty flexible stuff though. i guess that's all i can think of to describe it.

the idea definitely wasn't ours, a few others have done such but i think we're the first to take a few pics of the process.

bruceha_2000 · 09-26-2007, 03:37 PM

<div class='quotetop'>QUOTE(patsparks @ Sep 21 2007, 04:00 AM) [snapback]515658[/snapback]</div>

Quote:

It is a good tip and will stop bugs in those bug prone places.
[/b]

But then the bugs all get stuck in the screen and block the airflow anyway

In the winter I get lots of salt spray on the windshield. In the summer I get lots of bug splats on the windshield and dead bugs in the radiator. I noticed this when I put my engine block heater in 2 weeks ago. I am hoping they dry up and disappear.

apriusfan · 09-26-2007, 04:21 PM

<div class='quotetop'>QUOTE(bruceha_2000 @ Sep 26 2007, 12:37 PM) [snapback]518078[/snapback]</div>

Quote:

...In the summer I get lots of bug splats on the windshield and dead bugs in the radiator. I noticed this when I put my engine block heater in 2 weeks ago. I am hoping they dry up and disappear.[/b]

Dead bugs don't just dry up and disappear. If you can catch them before they get to the a/c condenser (like at the grill) a quick spray (for that matter, a blast of compressed air will work) from behind the grill keeps the a/c condenser protected and delivering maximum condensing efficiency.

jayman · 09-26-2007, 06:31 PM

I noticed the road debris issue soon after buying my 04 Prius. Frank Hudon had a great suggestion, the gutter guard stuff at Home Depot. The black plastic mesh blends in very well. I was able to attach mine from the front without having to remove the bumper.

As far as protecting the condenser from dirt and bugs, I used a commercial HVAC product from NuCalgon called Cal-Shield

http://ftp.nucalgon.com/ftp/prodlit/3-36.pdf

cairo94507 · 10-02-2007, 09:00 AM

Jayman- well you solved the problem, but geeze it looks kind of bad.
I did this mod about 18 months ago after a rock took out my AC condensor. Popped the grill out and installed the black netting with the real small cable ties and then cut the tails off. The only thing you have to do is clean the leaves, etc. out from time to time. But have not experienced any other problems and you really can't see the screen until you bend over and look for it. Simple fix and good preventative fix.

09-20-2007, 11:21 PM	#1
galaxee running WOT until out of fuel Join Date: Mar 2005 Location: central NC/ western WI Posts: 9,075 My Car: 2005 Prius Package: #5 Nominated 5 Times in 3 Posts TOTM Awards: 0 Friends: 21	we've been meaning to do this for over a year- today we got some screening put in the lower grill to protect the a/c condenser from flying rocks and such. because we make a number of long road trips and with our luck, we're best off doing all we can to protect ourselves against loss... carefully dropped the front bumper... lower grille removed. see how anything that makes it through that grille whacks the a/c condenser? ick! (recall the bumper is dropped, there's far more exposed normally.) we used some coated window-screen stuff and zip ties that have been waiting all year. DH melted holes for the zip ties with a very hot screwdriver. (the tricks you learn!) back side of grille: front side of grille: i'll have to post pics of the grille installed when it gets light out. we kinda got rained on (go figure, it's happened about twice this summer) and then it got dark out. eta: final result __________________ black 2005 prius, tweaked just the way i like it my diagnostic guy on electronics: "lack of troubleshooting ability is due to a high common sense rejection ratio."

09-26-2007, 06:31 PM	#9
jayman Senior Member Join Date: Oct 2004 Location: Winnipeg Manitoba Posts: 6,415 My Car: 2004 Prius Package: B Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 4	I noticed the road debris issue soon after buying my 04 Prius. Frank Hudon had a great suggestion, the gutter guard stuff at Home Depot. The black plastic mesh blends in very well. I was able to attach mine from the front without having to remove the bumper. As far as protecting the condenser from dirt and bugs, I used a commercial HVAC product from NuCalgon called Cal-Shield http://ftp.nucalgon.com/ftp/prodlit/3-36.pdf Attached Thumbnails

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09-21-2007, 02:13 AM	#2
ACORNBLUES Member Join Date: Mar 2007 Posts: 86 My Car: Package: Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	galaxee - i thought you have a car bra? Or maybe the one you have does not have a screen ... I have a lebra one and it has a screen over both the top and bottom grill. good tip though.

09-21-2007, 04:00 AM	#3
patsparks Uneducated bird-brain Aussie Join Date: Jul 2007 Location: Adelaide South Australia Posts: 4,905 My Car: 2004 Prius Package: Base Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 17	It is a good tip and will stop bugs in those bug prone places.

09-21-2007, 03:51 PM	#4
galaxee running WOT until out of fuel Join Date: Mar 2005 Location: central NC/ western WI Posts: 9,075 My Car: 2005 Prius Package: #5 Nominated 5 Times in 3 Posts TOTM Awards: 0 Friends: 21	the bra on our car doesn't have a screen on it, no. seems like a logical idea, eh? we weren't quite so concerned about bugs, i mean yeah there were far more bug impacts in the lower condenser than in the upper area, but our main concern is rocks that could punch a hole in it.

09-22-2007, 05:08 PM	#6
galaxee running WOT until out of fuel Join Date: Mar 2005 Location: central NC/ western WI Posts: 9,075 My Car: 2005 Prius Package: #5 Nominated 5 Times in 3 Posts TOTM Awards: 0 Friends: 21	DH punched holes in that lower grille in 3 places on the top and bottom (left, center, right) with a torched screwdriver. see the 3rd pic from the top, you can tell it's shaped like a screwdriver i actually got the mesh from some leftover supplies from a non-science project from our lab last halloween. nobody needed it after we were done, so i took it home. i'm not quite sure what it is, but it reminds me of cat-claw proof window screening except stronger. it's pretty flexible stuff though. i guess that's all i can think of to describe it. the idea definitely wasn't ours, a few others have done such but i think we're the first to take a few pics of the process.

10-02-2007, 09:00 AM	#10
cairo94507 Senior Member Join Date: Dec 2004 Location: San Ramon Valley, CA, USA Posts: 666 My Car: 2005 Prius Package: #6 Nominated 0 Times in 0 Posts TOTM Awards: 0 Friends: 0	Jayman- well you solved the problem, but geeze it looks kind of bad. I did this mod about 18 months ago after a rock took out my AC condensor. Popped the grill out and installed the black netting with the real small cable ties and then cut the tails off. The only thing you have to do is clean the leaves, etc. out from time to time. But have not experienced any other problems and you really can't see the screen until you bend over and look for it. Simple fix and good preventative fix.