1.) As I prepare to cut apart my grill I was just wondering if anyone (HomerTaco?) can offer some advice on how best to remove the triangles from the grill accurately. After inspecting the grill, it all seems pretty straightforward, but my Dremel obviously won't fit the angle needed to cut the triangles from the front. Could you tell me how you accurately remove the pieces for the triangle inserts? I have a tendency to overthink things like this and I'm currently envisioning drilling "marking" holes from the front to trace a template on the reverse and then Dremel it out, but surely there must be an easier way.
2.) As I didn't wish to sacrifice my "working" (read: non-destroyed) grill on this experiment, I ordered a replacement on which to complete the work. It came in two pieces, as expected; the outer surround and the insert - to be connected by melting points. Thing is...I have no soldering gun/iron...any suggestions on alternate ways to attach the two pieces? The redneck in me says blow torch and knife, but I don't want to trash my work if I can avoid it!
Any help you can offer would be gratefully accepted! TIA