Billet grille (or whatever)

Don't know if this will help anyone or not but since the digital camera was around I figured it can't hurt. Wanted to do something a little different with the front end and did not like the available options for a grille insert so I made my own. I also created a billet insert for the lower valance using the same technique.

After the honeycomb and center bar was removed, I heated the remaining plastic with a heat gun to form a "soft edge" for the new insert. Don't particulary like the hard edge that is left when the entire opening is cut out.


Picked up 9 pieces of aluminum flat stock, 1/8" x 1" x 3'. Using the vise and a rubber mallet I created a "master" curve that matched the grille shell.


Then I created 8 more that matched the curve of the master. Put all 9 in the vise and used a grinder with 40 grit disc to make them all match. Each was individually sanded with 100 grit paper to give a cleaner edge.


The ribs were then cut to proper length, spaced (staggered) front to back to allow fror the natural lean of the grill shell, then drilled for the threaded rod and spacers.


The end rods and middle rod fit into holes in the grille shell and were secured during final assembly. The other 2 simply hold the spacers. Note billet insert is recessed about 1/8" into grille shell.


Grille installed!