Nice looking grilles just aren't available for the B6 Passat. You can have the standard black plastic slats in the chrome surround (boring), the 'sport' chrome slats (horrible) or the R-line grille. Now the R-line is obviously the best option after market, but it's still not what I would call a really good looking sporty grille. Plus it's far too expensive.
So, do I buy an aftermarket badgeless grille? Nope, I hate them.
My only option then was to make my own...
I started with a really cheap one I found on eBay. Someone had sprayed it black already but had made a disgraceful job and wouldn't therefore fit it to their car :

My first job was to hack a couple of the slats out
Then I had to fibreglass the gaps and nitromorse the whole thing to remove the awful paint job

Then fill the rough bits out :

I sprayed the thing in filler primer to smooth it :

Once that was sprayed matt black, I fitted some mesh to the open areas:


Then I sprayed the chrome surround graphite grey metallic as I hate the chrome and didn't want black as my car is black.
Once it was all assembled, it looked pretty nice in my opinion :

So now I've gone from this :

And trial fitted the new one

Once it gets light outside, I'll fit it properly.
Any opinions on it?