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  Topic Review (Newest First)
Yesterday 06:32 PM
NashvilleTJ
Quote:
Originally Posted by Gojeep View Post
Awesome, glad I'm not the only one. Best thing is my wife now likes it as is now without extra adornment of the horizontal bars.

Your wife has a good eye...
Yesterday 05:51 PM
Gojeep
Quote:
Originally Posted by JoonHoss View Post
Waaaaay better proportions...Looks SO much better now!

Hoss
Awesome, glad I'm not the only one. Best thing is my wife now likes it as is now without extra adornment of the horizontal bars.
05-26-2020 08:31 PM
JoonHoss Waaaaay better proportions...Looks SO much better now!

Hoss
05-26-2020 07:31 PM
Gojeep
I tried the gravel tray at many different heights until I was happy. This is the position I have decided on. It is sitting 19mm-3/4" higher in front of the grille than before, but still leaving more distance from the bottom of the slots to tray.


Bumper back on to finally see if it was worth it or not. The distance from the slots to the top of the tray is now half that of slots to the top of the grille. This is the same proportions as the stock 48 flat nose grille which is different to the 58 pointy nose grille.


Ok, just put together a before and after. About 20 shots it took to get it as close as I could, even brought the dog in! So left the overall height of the grille the same, but shortened the slots by 50mm-2". Then raised the stone tray 19mm-3/4". Also the grille mesh has been added which helps more in the flesh than it does in these photos. I think it doesn't need the horizontal grilles bars to be added as well anymore.
05-26-2020 06:20 PM
Gojeep
Quote:
Originally Posted by jlcoble View Post
As always great work looks amazing
Thank you.
05-25-2020 12:18 PM
jlcoble As always great work looks amazing
05-24-2020 07:58 AM
NashvilleTJ
GrandWillys Project

Itís amazing how such a subtle change can have such a big visual impact. That looks very good - much less semi-truck looking.
05-24-2020 02:17 AM
Gojeep

Haven't quite finished putting it all back together but wanted to show the mesh installed with the radiator behind. Gives more security this way too as no way to release the bonnet catch except by the release lever inside the cab.
05-23-2020 05:39 PM
Gojeep
Quote:
Originally Posted by JoonHoss View Post
Any concern of not being able to get paint in between the mesh and the back of the grill slots, and having debris work it's way in between the contact points and casing corrosion/ rust?

Hoss
This just unbolts when it comes time for painting. I made it also sit hard against the bottom of the slots and will know at time of strip down if anything has collected during its bare metal period on the road.
05-23-2020 09:02 AM
JoonHoss Any concern of not being able to get paint in between the mesh and the back of the grill slots, and having debris work it's way in between the contact points and casing corrosion/ rust?

Hoss
05-23-2020 05:35 AM
Gojeep
I'd been thinking of ways to attach the mesh while keeping it taut. Was not sure if just using tabs welded to the back of grille bars would keep the top and bottom tightly in place. So looking at doing it this way.


The mesh I ended up using was branded SAAS and sold through Autobarn and others. https://www.autobarn.com.au/saas-bod...k-1200-x-280mm
I prefer this style of tin snips when you need to cut further into a sheet. These are made by WISS and they work like a throatless shear.


I thought it would look more professional if I curved the mesh to follow the back of the bars without gaps.


The mesh was not wide enough for my grille with the extra two slots. I had also ordered one that was, but it had a bit bigger diamond pattern that was less obvious. This one also has a twist so you must flip one side to keep it looking the same when run vertically. Viewed this way gives the most 'screening'.


To make the bends I put some tape down along the edge of the bench to save marking it. Then holding the ruler down, just bent it down using my hands. For the bigger radius curve, I bent it over some pipe.


I made sure the join was behind one of the grille bars. The pieces nest really well and could be held in place with the biggest rivet I could fit through the mesh holes.


I couldn't attach it directly below the grille slots as it would show through the front of the grille. By having it fold at the top and bottom, the fasteners will be less obvious.


I drilled and tapped some 3mm-1/8" aluminium sheet with the holes matching the ones in the mesh. Stainless steel button head screws then screw into these putting tension on the mesh. Worked so well that no additional fixing behind the grille bars was needed.


I ended up flipping the mesh so that the twist in it matched the angle of the grille so there was little obstruction when viewed head on. Also, the airflow now has a straight path. When viewed in front of the radiator it makes a bigger difference and makes it look less vacant. Will make more sense once I get shots of it all back together.
05-22-2020 06:23 AM
daddyjeep87 It definitely looks more balanced now with the same area above and below the slots.
05-21-2020 07:08 PM
Gojeep I'm putting up now what I did a month and a half ago before all the panel treatment and coil covers were done. Just waited until I could complete the write up once the mesh came in. Due to COVID-19, things that used to take 2 days, now take 2 weeks. Things that were 2 weeks, now take 2 months. Let alone anything from China that used to take 2 months!


Let the cutting begin! As I was not happy with the length of the slots, I am shortening them 50mm-2" back to the stock length. I am leaving the rest of the grille longer as need that to fit my radiator size.


Gives you an idea how the sectioning is going to work. I cut along the splice lines of the original extension that I had done.


I would have preferred to section the bead along with the grille slots, but the grille mounting bracket on the back gets in the way of doing it. So cut a slot up the middle of the bead, flattened it, and then rounded the end again with a sectioned piece of pipe.


Filler piece tacked in ready for welding.


As usual I checked to make sure each part of the grille was flat after welding. Can just see it drip down a fraction at the ends of this grille bar.


Made up a dolly from some bar stock and hammered down onto the table to stretch it out.


Now nice and flat again. All of them were checked of coarse.


From the factory, one side of each grille bar is longer than the other making it flat across the back to compensate for the grille angle. As I planned to fit some mesh behind the grille, I need to take care of the fact that the factory didn't press the last bar at each end this way as well. The reason is they needed the material on the opposite side of the slot to mount the radiator cowling. Rather than just adding a thin strip, it is better to add a wide piece, fully weld it, then cut it back to the right width. This controls the welding distortion far better.


The distance above and below the slots is close to the same now, 5mm-3/16" more on the bottom. Not the look I intend to keep though.


I can now adjust the height of the gravel tray until I like the proportions.


Think it is looking closer to the 48 grille above it rather than the 58 grille it started out as, which is what I wanted. Remember it is 2" taller and 9" wider overall with 2 extra slots added to make it the same number as the 48 grille.


A shot showing the various Jeep grille proportions through the years. Think I am closer now with the modifications but wont know until I have the Willys back together again.
05-19-2020 05:30 PM
Gojeep
Quote:
Originally Posted by NashvilleTJ View Post
Marcus - with all the metal working you do, how do you keep your hands looking so soft and smooth?

[emoji6]

Nice work on the intake - makes a world of difference.
Ha ha, just trailing a new cream for one hand only. Seems to have shrunk the hand as well!
05-19-2020 07:27 AM
NashvilleTJ Marcus - with all the metal working you do, how do you keep your hands looking so soft and smooth?

[emoji6]

Nice work on the intake - makes a world of difference.
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