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Unread 07-14-2013, 03:21 PM   #1
DRCracker
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2006 WK 
 
Join Date: Apr 2012
Location: Somerset, PA
Posts: 378
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.

TC

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Console XDs-45acp, Billet Catch Can, Airaid CAI Tube,
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Dark Khaki 2011 #9104 Wheels, Firestone Destination A/T 265/70/17's.
OME HD lift. Dark Khaki Matrix Brush Guard, Dark Khaki Painted Headlight Bezels.
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Unread 07-15-2013, 02:55 PM   #2
TurboDiesel
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looks good!!
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Unread 07-15-2013, 04:00 PM   #3
0321Nick
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Tip of the hat to you sir.


Where did you get the expanded sheet from?
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Unread 07-15-2013, 07:36 PM   #4
BurmaJack
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Nice job!
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Unread 07-15-2013, 08:16 PM   #5
DRCracker
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Thanks,

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.

TC
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MOLON LABE: 2006 WK Limited, Dark Khaki Pearl, 5.7 HEMI, QDII,
Console XDs-45acp, Billet Catch Can, Airaid CAI Tube,
1" Spacers, Steel Armadillo Sliders, Dark Khaki 4xGuard Front Skid,
Dark Khaki 2011 #9104 Wheels, Firestone Destination A/T 265/70/17's.
OME HD lift. Dark Khaki Matrix Brush Guard, Dark Khaki Painted Headlight Bezels.
Hemi Club #65 // Khaki WK Club #40

Last edited by DRCracker; 07-15-2013 at 08:17 PM.. Reason: misspelling
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Unread 09-19-2013, 09:31 PM   #6
Whit
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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.
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Unread 11-18-2014, 02:40 PM   #7
luckyse7ens
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I came across this on the expanded sheet grille thread. Do you have any better pictures of how this is attached?
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Unread 11-18-2014, 03:08 PM   #8
BoraBora
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Lol I was just looking at this earlier too and was wondering the same thing.
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Unread 11-18-2014, 08:41 PM   #9
DRCracker
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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.

TC
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MOLON LABE: 2006 WK Limited, Dark Khaki Pearl, 5.7 HEMI, QDII,
Console XDs-45acp, Billet Catch Can, Airaid CAI Tube,
1" Spacers, Steel Armadillo Sliders, Dark Khaki 4xGuard Front Skid,
Dark Khaki 2011 #9104 Wheels, Firestone Destination A/T 265/70/17's.
OME HD lift. Dark Khaki Matrix Brush Guard, Dark Khaki Painted Headlight Bezels.
Hemi Club #65 // Khaki WK Club #40
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