Join Date: Aug 2011
Location: Stratford Ontario Canada
Car: 2006 OBXT 5eat Newport Blue & 1997 SVX LSi Black Pearl
Feedback Score: 0 reviews
True, the Legacy grill is about 3/4" narrower in depth and sits above the bumper cover in the same mount points. Width of grill ring is the same.
I liked the look of the simple Legacy wings rather than the Outback's horizontal shelf support brackets. If you're patient and meticulous you can do this.
Got a '05 Legacy grill from the wreckers, studied the situation and went to work.
Dremel-sawed the centers out of both grills at the extreme edge where it joins the ring. I found a single unmounted hacksaw blade is more accurate and maneuverable for the final cuts. Also removed the black support 'stretchers', leaving just the grill ring. Note - the '05-07 grills are one piece molds with integrated chrome. I think the 08 & 09 you can separate the chrome ring but the grills are a different shape where they meet the hood.
You're left with 4 large side vacancies where the Outback center bars are molded in. Smooth down the edges and tape in exterior cardboard forms covered in tinfoil to shape & support the epoxy paste repair as it cures - you'll be pleased with the almost smooth surface. Using an epoxy compound Bumper Repair Kit and fiberglass cloth reinforcement I filled in & sanded out the ring sides and painted it graphite to match.
Legacy center wings & medallion are in one piece (Chrome sections can be unscrewed from the back so they don't get scratched during the dirtywork) If you cut out the wings correctly they are a darn near perfect fit inside the modified Outback ring (after fitting and trimming and refitting). I made it fit tight and square then pre-drilled screw holes each side and the thickness of the wing keeps it leveled out.
Back with a piece of matte black gutter mesh and add another screw or two if you like. Solid as OEM and I like the one-of-a-kind look.
True Subaru guys always take a second look and the questions begin...
Last edited by Old Davy; 11-16-2012 at 11:05 PM.
Reason: more detail