grill mod

I am looking at doing the satoshi grill mod to my new to me 05 dclb sport. my question is I have found some "expanding metal" at my local hard wear store. This stuff http://www.acehardware.com/product/...76&cp=2568443.2568451.2624969.2625784.2625950
My question is will this stuff work to do this grill mod? It is very sturdy it seems so I’m not too worried about it flexing. It will be painted black as well. If this wont work please let me know what would work out. I appreciate it.

 

^^^ first attempt at home made grill with expanded metal. I didn't like how it looked and it was sharp! I had a lot of cuts when I was done.

My second attempt is what is currently installed. Drilled aluminum sheet. cost me $45 total.

 

How difficult was that to do? That's a 12-15 grille right? And where did you get that drilled aluminum? I really want to do this. I just can't bring myself to cut up my grille without knowing how difficult it is.

 

Buy another grill, mod it to your liking, swap them out with no down time. Then sell or save your original. That's what I did when I put in my billit insert. BTW, IMO, the expanded metal you showed, the holes may be a bit large.

 

Did the same thing buying another grill to play it safe.I ended up doing the GrillCraft grill mod myself.Came out perfect!Still have the original grill and option to swap them out for a little change up from time to time if i want.

 

'12-15 grill it took me longer to find the correct tool to cut the plastic without having it melt than it did to deal with the rest of the construction. I did mine in about 2 hours not counting paint. There was a lot of measuring and cutting long and trimming down to make the best fit. There are a few write ups on here about where to cut etc. I was flying solo when I made mine then I found how helpful the how-to post are.

 

I have seen the how to section and feel I have a very good idea of how I'm going to progress with this mod. My question now is Toyko Joe where did you find the drilled aluminium? Also the expaded metal I'm looking it is really very strong when I tried to bend it I was un-able to do so.

 

Perforated sheet aluminum.
http://www.grainger.com/product/GRA...m/rp/s/is/image/Grainger/5PCY6_AS01?$smthumb$

The aluminum is sandwiched between the two pieces of plastic that make up the grill.
<- Center bottom mounting
<- left or right side mounting

<- back of grill showing tab cutouts for aluminum tabs to be sandwiched
^ red arrow: compression screw
yellow arrow: aluminum tab
blue arrow: painted plastic shroud


^Yellow red arrows are tabs only not sandwiched.
Yellow arrows are tabs sandwiched between back mounting plastic with tab cutouts and the front shroud



^bottom center tabs bottom view

 

i want to do this also , anyone tried the customcargrills.com one ? , looks pretty easy to do . On the website they have a video showing how to do theres .