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Unread 12-04-2007, 11:40 PM   #1
TheGillz
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Custom Mesh Grill A.B.C's

OK here is what I did to make a grill insert.

Went to lowes and bought an aluminum mesh screen door pet cover($22), can of high quality spray primer and paint($5 each), three boxes of picture hangers($1.75 each), loctite super glue gel($3), and stole the twist ties from the garbage bag box(kind of free).For a total cost of $40ish.

First i found that the screen was not wide enough to fit all the way across the grill in one piece, but it was more than twice as wide as the grill is virtically so i cut it in half. I used one half to cover 6 of the grill slats and a piece of the remainder to cover the 7th.

I removed the grill (see other threads for instructions) and set it front side down on my table and took the big piece of mesh and firmly pressed down with both thumbs along each slat so that the mesh would bulge outward toward the front. Repeat with last slat piece.

Once the mesh was molded to the shape of the grill I sprayed 2 coats of primer and 3 coats of gloss black on it and let it dry for the amount of time the can asked.

While the mesh dried I super glued the picture hangers three on each side of each slat to the back side of the grill.

Works great!


Like this.


Almost done with that.


After all those were in i got the smaller piece of mesh to test the theory with and set it in the 7th slat and used the twist ties to hold it toward the front of the grill by puting it through a hole in the mesh, through the gap in the picture hanger and back out a different hole in the mesh and then twisting it tight.

Here's what I used for that.


Here it is tied down.


And the test look from the front.


I found that it was snug and looked good so I repeated with the large piece of mesh. The middle picture hangers are a pain because you need a toothpick or tweezers to get the twist tie to come back up through the mesh, but with patience it works famously and I've been driving and wheeling with it for a couple weeks and still looks new!

Here's the finished product!


And one in the bush for fun.


Hope this gives you all some good ideas.

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Last edited by TheGillz; 12-07-2007 at 03:26 PM..
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Unread 12-05-2007, 12:10 AM   #2
ge2
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Looks very very nice indeed!!

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Unread 12-05-2007, 03:40 AM   #3
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very nice, i like it!
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Unread 12-05-2007, 12:51 PM   #4
TheGillz
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Thanks. Its these types of mods I can afford right now. Maybe get some other high $$ stuff when I get my taxes back.
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Unread 12-05-2007, 01:39 PM   #5
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Looks really good, good write up too, I think I'll be doing this soon!
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2008 2dr JK
Mod List (So far)
OME HD Lift with NitroCharger shocks. JKS front and rear adjustable trackbars. 33" Toyo Open Country MT's on 18" XD Rockstars. JKS Quicker Disco's. RockHard 4x4 Oil Pan Skid. Shrockworks Rock Sliders. Woods SS relocation bracket & evap relocation bracket. sPod switch panel. Tuffy Security Cover

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Unread 12-05-2007, 02:41 PM   #6
JYogi
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How do you open the hood latch after this is installed?
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Unread 12-05-2007, 03:09 PM   #7
TheGillz
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The same way you open it before it was installed.

Undo the tie downs, lift hood aprox two inches, stick finger under hood and move hook over, lift hood.
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Unread 12-05-2007, 10:24 PM   #8
JYogi
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K, I always opened it from between the grill...
Just went out and saw I can do it this way, thanks!
Now I am gonna put this on my JK!

I have the WeatherTech Floor lines, they are GREAT!
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Unread 12-07-2007, 03:30 PM   #9
TheGillz
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Holy cow...now you can see the pics. I am dum.
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Unread 12-07-2007, 03:33 PM   #10
JYogi
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Looks great but I do not think the baggie strips will hold long term
and I wonder about the picture hangers.

Zip strips and the plastic squares meant to keep wire together
seem to be a better way to go.

There was someone who posted this same thing a couple mths back with the method I listed.
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Unread 12-07-2007, 03:40 PM   #11
TheGillz
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Hmm, well i wanted to be able to easily replace the mesh once it takes a couple rocks and or whatever else might damage it. And keep it cheap. I almost epoxied it to the back of the grill. Glad i didn't.
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Unread 12-07-2007, 05:17 PM   #12
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Im really liking this mod.I priced around for these and couldn't believe what they were charging .My only question is how difficult is it to remove the grill cover?
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Unread 12-07-2007, 05:25 PM   #13
TheGillz
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If you mean "how difficult is it to remove the grill" it isn't, unscrew and pull out the 6 or 8 plastic screw faseners(sp) along the top of the grill, then unhook the blinker lights, then I took a beat up chisle I had and put in the crack of the remaining snap on holders along the bottom and twisted, it snaps right out. You can see them really well in two of my pics.
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Unread 12-07-2007, 11:05 PM   #14
JYogi
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Quote:
Originally Posted by thegillz
Hmm, well i wanted to be able to easily replace the mesh once it takes a couple rocks and or whatever else might damage it. And keep it cheap. I almost epoxied it to the back of the grill. Glad i didn't.

Good point but check out home depot a pack of small zip strips is just a couple bucks and thats all you will be replacing when you change it that way...

I have just had things break using the bag ties before...

Doing it with the squares others have in the past and zip strips (minus the cost of the mesh) would be well under $25 (could even be 10 bucks). Replacing the zip strips when you change/repaint the mesh would be under 5 bucks each time...

Anyway thanks for putting together a good step by step with detailed photos and giving us more options!

Hope you don't take a little constructive criticism the wrong way.
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Unread 03-25-2008, 03:17 PM   #15
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Quote:
Originally Posted by TheGillz View Post
If you mean "how difficult is it to remove the grill" it isn't, unscrew and pull out the 6 or 8 plastic screw faseners(sp) along the top of the grill, then unhook the blinker lights, then I took a beat up chisle I had and put in the crack of the remaining snap on holders along the bottom and twisted, it snaps right out. You can see them really well in two of my pics.

you aint kiddin'....... but I did try the chisel route (for the bottom tabs) and twern't working to well for me....just pulled from verrrrrry close to each tab and they came loose. Aint NOTHING like the feeling yer' "Gonna break something" on a brand new vehicle but out they popped......

I'm in the middle of the install right now...awaiting the glue to dry.
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