Ok here is kind of an explination of what I did. First off it should be obvious that you can't use bondo or Fiberglass to cover the whole because the bumper flexes, and bends. I used this
SpaceAgePaint - Au-ve-co Flexible Epoxy Compound but there are lots of products that does the same thing. This stuff has lots of flex to it. It actually has too much flex (i'll explain this)
-First I took a piece of cardboard and cut it to the exact same shape as the nostril. Then I taped it from the inside of the bumper so that it was a little inset from the edge. This will give your bumper repair stuff something to kind of mold to and also some thickness.
-Then I popped out the dodge emblem so that I could fill that in. Mine had a dime size hole behind it so I had to use some mesh they make for this kind of repair (you buy it the same place you get the repair stuff).
- Then I took a dremmel to rough up the edges around the nostril to give the filller something to hold onto.
- Then I put a thick layer of filler onto the cardboard. The filler will be a little heavy for the cardboard, so it will create a flat surface that doesn't go with the curve of the bumper.
- To make it curve around the same as the bumper I lined the back with fiberglass. That will give it lots of strengh and you can shape it to that curve. Of course you want to wait for your filler to be completely dry before you do this. That should be obvious. How I shaped the fiberglass was: before it dried I wedged a socket ( I don't remember the size. Just one big enough to give it the right curve) between the top of the now dried filler and the top of the bumper that screws to the car. Now with that done, I just let the fiberglass harden.
-after the fiberglass hardened I put another layer of filler over the layer that is dry. This layer I extended it down towads the bottom of the nostril, and out on both sids of the nostril so that I could feather it out really good.
- From there it was just lots of sanding to shape it and get it smooth. Shaving the dodge badge is easy. Just fill in the space with the filler then sand smooth.
That is a pretty simple explination of what I did. It will still be trial and error I'm sure, but that is what I did. I will post up a few pics of the things that I couldn't explain really well when I get off work.
There may be a better way to do this, but this is what worked for me, and I had never done any body work before in my life. I'm actually going to paint it myself too, and I have never done that either. So it has all been just learning on my own.
On a side note. The notches that exist where the crosshairs once were was also filled in with this filler for a clean look. ask if you have any questions.