Homemade Grille idea. HELP

OK... im trying to make a homemade grille and ive gotten it cut. But i hade an idea i want to --->SOMEHOW<--- make a 1inch thick border around the edges of the grille. and then ill stick bolts through the front and nuts on the back to make it look like the RBP grille's border. but i cant decide how to make a border or what to make it out of. Does ANYONE have any idea of what to use or how to do it? Thanks for any help... and yes im going to paint it black.

 

thin sheet metal

 

Only problem is bending it for the curved edges, do you think it'll bend to fit?

 

Sawzall. No bending required. Just trace (I guess) the grill opening onto the sheet metal and have at it.

 

Good idea about tracing on the sheetmetal, but Sawzall's a little violent for trying to cut it precisely haha.

 

The flat plastic that stereo installers use for mounting speakers to panels. Not sure what the name of it

 

bro.

 

you could fab it from a sheet of ABS Plastic & then heat weld it to the mesh.
that would be the easiest & most cost effective IMO.
I precision sheet metal shop could make you just about anything you want but your talking serious $$$
I'm not wild about the look of that grill so I haven't attempted a replica.
I'll take a whack at a 01-04 satoshi here myself soon.
Best of luck!

 

Dremel.

 

I built one similar to an rbp grille, actually still in the process. Used a sawzaw and a bench grinder youll just have to do some welding. Id like to see pics of yours if you ever got one made