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Discussion Starter #1 (Edited)
Though somewhat rare, pebble/stone radiator punctures can happen to any car, including the Volt. I (and now GM for MY 2013-2014) agree that a bit more protection would be helpful.

Road debris, whether pea sized pebbles, gravel, or rocks can puncture the battery coolant radiator with a unlucky “lucky” shot through the Volt's lower air intake louvers. This can be a $1500 - $4100 repair and is not a warranty item, though some dealers have been more sympathetic than others on this point.

So some owners have added an extra layer of protection to their car in hopes of avoiding the need for this type of repair.

$30-$300 GM Retrofit ?
Some have said that 2013 and 2014 models come standard with a plastic screen (see diagram below) mounted behind the grills and in front of the radiators, but that earlier model years do not have this screen. However, getting down with a flashlight and peering into the air intake I see that my 2011 also has this plastic screen. So do the 2013/2014 models have yet another screen? A different one? Or do all years have the same screen? To have a dealer install the screen is about $300. Or the parts are about $30 for those who can do it themselves.

Though some may question whether the plastic is up to the job. The injection-molded plastic screen appears designed to distribute the energy from rocks and small road debris over a larger area of the radiator fins to protect the coolant tubes from puncture. I'm sure it's better than nothing and may be quite adequate except against smaller pebbles.

$25 GM Part 22856576
http://www.gmwholesaledirect.com/oe-gm/22856576
$0.44 Screen Clip (10121502) (not sure how many are needed)
http://www.gmwholesaledirect.com/oem-part/chevrolet/volt-parts/2013/base/1-4l-l4-electric-gas/cooling-system/radiator-and-components/screen-clip/10121502




For details see http://gm-volt.com/forum/showthread.php?68897-Radiator-protection-service-bulletin&p=1145426#post1145426

$12 DIY Exterior Screen (or have one made for you)
A few years ago I took the added step of installing a screen to the lower air intake grills of my 2011 to hopefully reduce the chances of a pebble puncture “lucky strike”. My solution cost me $12 and a few hours tinkering. After two years, I see some of the black paint has been knocked off by impacts with stones or pebbles (I assume), so maybe it is helping.




VOLT Radiator Protection Screen exterior screen.jpg

See this link for more details: http://gm-volt.com/forum/showthread.php?35945-My-12-Air-Intake-Rock-Screen

VoltScreen
Here is a link to a site by another GM-Volt member (also named Steve) who is selling these as "VoltScreens" finished and ready to use: http://http://voltshelf.weebly.com/new-voltscreen-radiator-protector.html

Here is a variation using a 4" wide strip of 1/4 " hardware cloth installed behind the air intake grill by pulling 4 push pins on splash pan and slipping the wire cloth in behind the grill attached with many small zip ties.

VOLT Radiator Protection Screen interior Wire Mesh.jpg

http://gm-volt.com/forum/showthread.php?104081-Plastic-Floor-Pan-Damage&p=1513745#post1513745
 

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Discussion Starter #2 (Edited)
$15 Nomex Honey Comb Radiator Protector
Others have created their own version from Nomex honeycomb:



View attachment 48865 View attachment 48873

Plan on replacing the Nomex protector after 3-4 years as bugs and trash accumulate, or the honeycomb tubes get bent.

Besides removing the 4 plastic push pin fasteners, several fasteners that secure the air dam must be removed since the ends project upward and get in the way when sliding the screen in place. The Nomex honeycomb protector is flexible enough to work up through the bottom opening with the bottom plastic. A 27.5”- 29 “inch width is wide enough to overlap the edges of the radiator on each side and is snug enough to bypass using the plastic ties included with the protector. A 12”-19” height appears to cover the whole radiator too.

Nomex http://www.speedwaymotors.com/Honeycomb-Radiator-Protector-22-X-31-Inch,29469.html

For details see http://gm-volt.com/forum/showthread.php?68897-Radiator-protection-service-bulletin&p=1397921#post1397921

Reference Posts
http://gm-volt.com/forum/showthread.php?68897-Radiator-protection-service-bulletin
http://gm-volt.com/forum/showthread.php?104081-Plastic-Floor-Pan-Damage&p=1513745#post1513745
http://gm-volt.com/forum/showthread.php?35945-My-12-Air-Intake-Rock-Screen
http://gm-volt.com/forum/showthread.php?10234-4100-repair-over-a-road-pebble
 

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Chevy Volt Protection Grill 002.JPG Chevy Volt Protection Grill 001.jpg

I ended up doing this for $35. I ordered everything from Ebay. Cutting it to match though was tougher than i expected. That bend is not as easy as it looks. :rolleyes:
 

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Discussion Starter #4
View attachment 50362 View attachment 50370

I ended up doing this for $35. I ordered everything from Ebay. Cutting it to match though was tougher than i expected. That bend is not as easy as it looks. :rolleyes:
Yours looks like it ended up fitting well, firehawk72. I have a PDF cutout pattern here: http://gm-volt.com/forum/showthread.php?35945-My-12-Air-Intake-Rock-Screen&p=461777#post461777http://gm-volt.com/forum/showthread.php?35945-My-12-Air-Intake-Rock-Screen&highlight=air+intake

But yes, after cutting I did have to gently squeeze the screen to give it a slight vertical radius so it bows out and this also helped me curve the piece horizontally to match the slight curve of the bumper. This also gives the screen some extra strength.
 

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Though somewhat rare, pebble/stone radiator punctures can happen to any car, including the Volt. I (and now GM for MY 2013-2014) agree that a bit more protection would be helpful.

Road debris, whether pea sized pebbles, gravel, or rocks can puncture the battery coolant radiator with a unlucky “lucky” shot through the Volt's lower air intake louvers. This can be a $1500 - $4100 repair and is not a warranty item, though some dealers have been more sympathetic than others on this point.

So some owners have added an extra layer of protection to their car in hopes of avoiding the need for this type of repair.

$30-$300 GM Retrofit
GM has come out with a plastic filter for installation behind the grills and in front of the radiators. Apparently 2014 and 2013 models come standard with this additional filter. Earlier model years do not. To have a dealer install the screen is about $300. Or the parts are about $30 for those who can do it themselves.

Though some may question whether the plastic is up to the job. The injection-molded plastic screen appears designed to distribute the energy from rocks and small road debris over a larger area of the radiator fins to protect the coolant tubes from puncture. I'm sure it's better than nothing and may be quite adequate except against smaller pebbles.

$25 GM Part 22856576
http://www.gmwholesaledirect.com/oe-gm/22856576
$0.44 Screen Clip (10121502) (not sure how many are needed)
http://www.gmwholesaledirect.com/oem-part/chevrolet/volt-parts/2013/base/1-4l-l4-electric-gas/cooling-system/radiator-and-components/screen-clip/10121502




For details see http://gm-volt.com/forum/showthread.php?68897-Radiator-protection-service-bulletin&p=1145426#post1145426
Hmmm...

I checked on my early manufacture 2012 Volt (1831 last 4 digits of VIN), and part 22856576 is already there. The diagonal structural pieces, etc, on the part in my car look just like the diagram in the original post, and I bought my Volt new.

Any thoughts on what is going on? :confused:
 

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Discussion Starter #7
Just had a look at mine (2013) Don't see any clips and it looks to be not much in protection.
Hmmm. I agree, doesn't look like much extra protection.
 

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Thanks for bringing this thread up, Steve.

Agreed on the pic and note by HouseApe. I have it on my '13 as well, and doesn't seem to offer much protection. I even have bent fins showing already. It could offer protection against anything larger though, maybe.

Might try your technique, Steve. Seems simple enough, and a good extra layer of protection.
 

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The screen effectively covers the radiators liquid channels (which run horizontally from left to right).
In that respect it's aligned perfectly to protect from rock strikes.

The vertical fins that run from upper to lower liquid channel don't carry any fluids so rock strikes there wouldn't damage the radiator.
 

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I beleive in a little extra protection.


Thats why I have a ShamWoW on my nightstand.
 

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Discussion Starter #11
Getting down with a flashlight and peering into the air intake I see that my 2011 also has this plastic screen. So the idea that only the 2013/2014 model have this seems incorrect.
 

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Getting down with a flashlight and peering into the air intake I see that my 2011 also has this plastic screen. So the idea that only the 2013/2014 model have this seems incorrect.
I finally had a chance to check both of mine. My 2011 Crystal Red Volt does not have the plastic screen, but my wife's 2011 White Diamond Volt does have the screen. It could be the result of a change at some point during manufacturing (the wife's Volt has a later VIN), or maybe the body shop forgot to put it on when they repaired my Crystal Red Volt after a deer encounter.
 

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I finally had a chance to check both of mine. My 2011 Crystal Red Volt does not have the plastic screen, but my wife's 2011 White Diamond Volt does have the screen. It could be the result of a change at some point during manufacturing (the wife's Volt has a later VIN), or maybe the body shop forgot to put it on when they repaired my Crystal Red Volt after a deer encounter.
'
My 2013 does not have a plastic screen. Just the ribs of the lower black plastic bumper...
 

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Discussion Starter #15
'
My 2013 does not have a plastic screen. Just the ribs of the lower black plastic bumper...
Hmm, so it seems like it's a random thing as to whether your car has this extra GM plastic grill or not. Very odd.
 

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Great. Something else I need to do before I drive 1,000 miles on a dirt/gravel road.
Yes you do. Driving to my parents involves 3 miles of gravel road. Christmas Eve, a small limb had fallen to the road. Was curved just enough to allow the end of it to line up with the radiator. Fortunately, only the battery was affected. I was able to drive to the shop on the 26th. $1700 parts/labor.
 

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Yikes. Sorry to hear that RGaley.

Trying to prevent that from happening to myself, especially in the non-cell-phone wilds of Northern Canada.
 

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Can you take and post a picture. Unfortunately, I am not near our Volt at this time.
Pictures taken by HouseApe are in the post I linked.
 
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