Are you planning on painting the grille? If so I'm curious to see how the paint lays inside the 'R' in 'FORD' since the gaps are so tiny.
I am not seeing that as much of an issue, I paint small stuff all the time. Generally I use a filler primer, then a 2x coat paint. However not this time around. I plan on making the finish clean enough with priming and sanding, then using an airbrush to get even paint coverage, then protecting with a good clear coat.
But to answer your question, if I am concerned about the gap, I will preheat the plastic to 100 ish degrees(f), then use a hair dryer,(not a heat gun) to help the paint flow and not bridge the gap.
I am starting the priming process, to get enough so I can sand, now. I will take pictures along the way so you can see how it turns out. Of course I will provide updates as to how it was handled, or mishandled.
This thread certainly wont be one of those threads where everything is perfect. I am not embarrassed about failures or poor craftsmanship. This is a learning experience that I am hoping to share. I can already see by the interest and response that I should get good feedback from the forum, which is only going to make this project better.
So thanks for all the comments so far, and in advance for any comments that may come.
If anyone has request of what they want to see just ask, I will take pictures and post them.