My thoughts awhile back about lower grill
 

https://www.chevyhhr.net/forums/show...ighlight=grill
I've made the recommendation awhile back...
Even with it.. I noticed some substanial hits taken to it but , no intrusions .. have again awhile back...., modified the material used....

It doesn't look very close net in spacing, and intrustions could still be possible.. or is there fine mesh behind it ?

I used fine mesh ... Stainless number 10 x .025 temps varies from 185 - 190... no cooling problems..

http://i37.photobucket.com/albums/e7...cs/fnemesh.jpg

Well, I finally feel compelled to put my two cents in on this thread:
The 'industry' as a whole (Chevy, Honda, etc.) does not put a grille there because it's cheaper for them not to do so. The number of complaints/repairs/warranty work that actually gets approved is way less than the cost of putting a grille on every vehicle. While I am by no means supporting the 'industry', I am also trying very hard not to take sides. I support my HHR BretHHRen first and foremost, but I have also seen the other side of the story:
In my previous life, I worked for a retailer for 15 years. People brought in products all the time because, in their opinion, they were flawed or did not last as long as they thought they should. Our policy consisted of sending the product back to the manufacturer and have them evaluate it. Sometimes the customer got a new product, other times the manufacturer deemed that the product had performed as designed, and sent the used product back. This process was handled on a case-by-case basis. The majority of times, though, the customer simply felt that they were entitled to more, because they paid good money and felt (again, in their opinion) that they deserved more.
While in SoCal's opinion (and many others, I assume), this is a design flaw, I seriously doubt that Chevy/GM will see it the same way. This is because they would have to admit a mistake on their behalf, would have to perform a recall of some sort, and provide a grille (or some other product that would do a grille's job adequately) to EVERYONE that has purchased an HHR thus far. Think this will happen? Sorry, but not in our lifetime. This is because rocks hitting the condenser or radiator WILL cause SOME problems, but it will be cheaper for Chevy/GM to address such issues on a case-by-case basis, since this will not occur to every HHR on the road.
I wish Mike the best of luck, and hopefully he's one of the lucky ones that will get the work done on GM's account, but I also wouldn't hold my breath on it. My prediction is that they will meet halfway somehow, and Mike will have to shell out some money for the repair. Good Luck!
That's my :2cents:

Here's an assortment of your 'typcial' grill mesh's... there's better out there (more $$$) and there's worse. :thumb:

http://www.customcargrills.com/

(Look under GRILL MESH for a variety of styles)

External lower grille
 

:thumb: Ditto for me! If the price is right and it's not too big a hassle to install I'm in for one!:banana:

Here are some pics:

From the front (nothing visible):

http://www.socalhhr.citymax.com/i/Hi..._Front_640.jpg

Up behind the bumper:

http://www.socalhhr.citymax.com/i/Hi...Damage_640.jpg

Size of damage (compared to Quarter):

http://www.socalhhr.citymax.com/i/Hi...Damage_640.jpg

As you can see, the damage was cause by a pebble smaller than a dime.

Better get some protection on there quick! You're next.

(Still no word on whether they will cover it.)

I'll keep you posted...

Mike, I been reading this post very carefully and I think I will call my dealer tomorrow and the salesman I know and see if they have had any problems with this.

Mike, I hope that you get this resolved quick and satifactorally. If every one would present this to their Chevy rep. Maybe something can be done for this problem in the future.

Er, Mike....:bow: . Maybe you need a running board in front??? :eek:

Mike......... Mike nnnnnooooooooooooo not that!! :eek:

Tom - we don't even have deer around here! :lol:

Move up here, you usally don't need the AC. and bring a jacket if you come..