HOW TO: Mesh Grill - DNG's version

I've gotten a couple requests to write a "How To" for my version of a mesh grill, so here it goes.

EDIT: If there are enough people who want these, I can make a couple for some price I haven't decided yet. PM me if interested.

Materials:

• Screen door mesh from Home Depot
• Foam posterboard
• Rustoleum High Heat spray paint
• Cutting tool for grill assembly (dremel, hand saw, etc.)
• Cutting tool for mesh (some kind of heavy duty scissors)
• Rivet tool + rivets
• Drill

1. Cut out insides of grill assembly and file down until relatively flush




2. Make a template out of foam posterboard to mold the mesh around. When making the foam template, I recommend making it a couple millimeters smaller, leaving a bit of tolerance between the foam template and grill assembly to allow for the mesh bends to fit inside. Foam posterboard seems to be the ideal material to use, as it is easy to file down to make precise adjustments




I also recommend making as many cuts as you can around the corners to make them as round as possible (make adjustments as necessary)


3. Insert molded mesh into grill assembly, drill holes, and install rivets. I recommend drilling for one rivet at a time, to allow for minor adjustments. No pictures, sorry.

4. Spray paint radiator with Rustoleum High Heat spray paint.

5. Enjoy

 

looks awesome
how much did it end up costing?

 

looks great, i wanna do this to my 96

the one step i want pictures for and nobody every puts up pictures.

 

~$60 for the grill
~$20(?) for the mesh
~$5 for the paint

If I make another one, I'll be sure to snap pictures of that step.

 

Not that hard man. Im sure you can do it. Its pretty strait forward.

Looks great man!!! I will be doing this soon as well

 

How did you make sure the grill curved with the rest of the front end? or did you just keep it flat?