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DRCracker 07-14-2013 03:21 PM

Lower Grill Expanded Metal Insert
I was able to make an aluminum lower grill insert fairly easily.
The toughest part was removing the bumper cover,
but that is comparatively quick and easy.

I purchased a sheet of 3/4" expanded aluminum from a local truck body shop.
Cost about $35 for 3'X3'. I chose aluminum because it would be lighter, easier to bend, less likely to corrode quickly, and strong enough to offer some radiator protection.

Measuring the lower grill opening and the angles I came up with a pattern.
36" in length, 4" top section,' 4.5" middle section, 1" lower section.
Upper angle approx. 140 deg., lower angle approx. 40 deg.
Primed, painted, clearcoat. Would work easily with bedliner or any paint.

The insert fits into and around the lower opening and was secured with ss bolt and nylock nut and washer above insert.
This will not work with a front receiver and it was secured in a similar fashion from the bottom in that case.

The aluminum is easily trimmed with snips to allow clearance for tow hooks or matrix fittings.

Sorry the light is not good and the photo's don't show the insert well,
but as it is Dark Khaki, it is hard to see here.

Good luck.:thumbsup:


TurboDiesel 07-15-2013 02:55 PM

looks good!!

0321Nick 07-15-2013 04:00 PM

Tip of the hat to you sir.

Where did you get the expanded sheet from?

BurmaJack 07-15-2013 07:36 PM

Nice job! :thumbsup:

DRCracker 07-15-2013 08:16 PM


The local Lowes had no idea what I was looking for.

I purchased it at a local Truck Fabrication shop, named J&J Truck Bodies.
Try your local shops that use these products, farm supply, etc.


Whit 09-19-2013 09:31 PM

Thanks for that mod!
I will be doing this and glad you did it that way. I started to look into it but no time to take the cover off and explore.

luckyse7ens 11-18-2014 02:40 PM

16 Attachment(s)
I came across this on the expanded sheet grille thread. Do you have any better pictures of how this is attached?

BoraBora 11-18-2014 03:08 PM

Lol I was just looking at this earlier too and was wondering the same thing.

DRCracker 11-18-2014 08:41 PM

It is secured with nuts and bolts through the upper fascia.

I drilled two holes in the upper lip of the bumper cover as you can see in some of the photo's.

The profile of the metal bends under the opening at the bottom and is bolted above the opening at the top.

If you look carefully at the photo's you can see the two bolts and the lim in the metal going underneath the grill opening.

I hope you can see it.

Even after snipping out parts for the tow hooks, the metal was still very secure.


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