did you test fit your hadndi-work on the car yet? I remember trying this same project a few years ago and the issue I had was that the top of the grille doesn't meet the actual hood, it has a gap almost the same distance and there was between each of the horizontal "slats" in the stock grill for a look of continuity.... when I made mine and put it on that gap made it look like a poorly-fitting chinese part.
My majorly huge hand-made Focus RS replica build:
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My RS conversion is For Sale: http://www.focusfanatics.com/forum/vehicles-sale/578185-sale-rs-mk1-conversion-2003-focus-svt.html