OK, finally had a chance to take some pictures. I used black coroplast and some black nylon "TouchDown Clamps" made by Sioux Cheif that I bought in the plumbing department at Lowes.
Here's a shot of the lower grill block:
You can also see the plug for my Engine Block Heater on the left. The 3-pronged plug is covered with a plastic cap when not in use.
The TouchDown clamps are also available at Ace Hardware:
550-11PK2 TouchDown Clamps
and come in a packet that looks like this:
They use a "zip tie"-like tooth/groove system to lock in place, and this size is perfect with 1/8" coroplast.
Here are some other shots of the grill block:
I think it looks pretty good. Blends in very nicely and the clamps are hardly noticeable.
The only thing I would have done differently is to mount the clamps from the inside on the lower grill, so that they can be removed more easily. You have to insert a flathead screwdriver into the ends to release them, and that'll be very hard to do from the inside!
Eph