Grill Mod
 

[IMG]http://my.project-jk.com/data/505/thumbs/DSC02116.JPG[/IMG]
[IMG]http://my.project-jk.com/data/505/thumbs/DSC02130.JPG[/IMG]

I cut a piece of expanded aluminum metal 15" x 28". Primed and painted satin black and then notched out around the retaining clips for the grill, I used self adhesive zip tie blocks and trimmed them to fit between the grill slots. I used 3 on each slot of the grill and 3 on each end, all of them evenly spaced and used black zip ties to secure the grill insert in place.
All the materials came to around $25 or less.

thanks thats next up on my list of must do's.

mark

Looks fantastic man. Where can I get my hands on the self adhesive zip tie blocks? Maybe theyre available in any auto parts store, but i dont recall seeing them before.

I bought them at a Taylors hardware store.

That turned out great. I may have to do this to my Jeep as well :D

I ordered mine through www.mcmaster.com
type in sheet metal
Click "Sheet Metal Products:
Click "Sheets,Bars,Strip, Cubes"
Thats for the sheet- 28.5x14

Part # 7582K12 for the zip tie cubes in black

I used Brake cleaner to clean the grill and black caliper paint to paint it.

Paint first so its ready for install!!



I Took out the 6 plastic screw- did by hand - hint hint
http://i93.photobucket.com/albums/l6...8/DSC06734.jpg

Pulled gently by the blinker- not to hard now its still connected
http://i93.photobucket.com/albums/l6...8/DSC06735.jpg

Pulled red tab out FIRST- then pulled plug out
http://i93.photobucket.com/albums/l6...8/DSC06736.jpg

Pulled bottom out
http://i93.photobucket.com/albums/l6...8/DSC06737.jpg

Have grill ready
http://i93.photobucket.com/albums/l6...8/DSC06740.jpg

Laid all the tie downs - 3 going down and one on each top hole
http://i93.photobucket.com/albums/l6...8/DSC06741.jpg

Zip tied each one using a small screwdriver to help get the tie up
http://i93.photobucket.com/albums/l6...8/DSC06744.jpg

Re Install the grill and Vuala!!
http://i93.photobucket.com/albums/l6...8/DSC06746.jpg


THANKS Ponpeta!!!!!!

Thanks! I like the different patterns McMaster has to offer....

Added more info above
 

hope it helps

very nice guys, ill be doing the same, thx for the write up :yup:


Bamo

Excellent mod and write-up guys! Just did it myself and looks great!

As an fyi to others, you'll notice the grill is slightly bowed out, and when putting the screen insert in, you'll be best off trying to curve the expanded metal 'before' painting and installing -- that is only if you care and want to keep the entire bow in the grill.

As I was moddin' it, I checked a few times from the other side to see how it looked... Since my expanded metal was not curved, I figured it would bend to the grill -- but the grill bent to the metal... It doesn't look bad at all, I'm just a little too anal sometimes. The center sections of the grill are more flat now... Which... if you really think about it... this is two mods in one -- grill insert and grill flattener - like the previous jeeps (although the slant remains).. :)

nice
:D :yup: :yup:

for anybody that did this mod.
 

Do you think that doing this mod in 7 diff. pieces would keep the grill from bowing? I was thinking of making a mold ( one slot of the grill ) out of wood and bending the wire to fit each slot, it wold look just like yours but alot more work. Do you think it's worth the extra effort?

Nope. In my opinion not worth the time or the pain! The bend is not that noticible anyway after it's complete... I should have measured the original depth of the bow, but I would say it was only flattened about 1/4".

Either way, this was an excellent idea & mod, and it looks great flattened a little or not.

What size are those cable tie squares? Are they an inch by and inch? Do you rememember what strength cable ties you used. Just curious because I know they make different strengths. Thanks

Use 1"x1" it fits perfect

Dont use steel- it rusts to quickly because its always rubbing on the grill itself.

Use aluminum!!

with the bow just make sure the panel isn't to thick.

Extra expanded Aluminum
 

Just completed this mod today and it looks great.

The only problem is I had to buy a 4'x8' sheet of the aluminum. So I have eight extra sheets 15"x28" of expanded aluminum. Not looking to make any money so I will part with them at cost plus shipping. Pm me if you are interested.

Extra expanded Aluminum
 

Here are the pics requested.

http://i94.photobucket.com/albums/l9...p/grill003.jpg

http://i94.photobucket.com/albums/l9...p/grill002.jpg

http://i94.photobucket.com/albums/l9...p/grill001.jpg

http://i94.photobucket.com/albums/l9...p/grill004.jpg

just got done with mine.

thanks mark

http://i177.photobucket.com/albums/w...jkjeep8003.jpg
http://i177.photobucket.com/albums/w...jkjeep8002.jpg
http://i177.photobucket.com/albums/w...jkjeep8001.jpg

Nice MOD. I got everything i need to do mine, will hopefully paint them this week and have it installed this weekend. I'm going to go with that matching paint idea ..... Black JK 4 door, so i think i'll paint it black ... lol, sounds good to me.

I got the same pattern as purple1 1haze and some other guys but im going to run it in the other direction. I'll post some pics when its done. Anybody else with that pattern do this? pics? links?

Where to buy?
 

Where are you guys buying your aluminum? I'm having trouble finding it locally. Don't really want to order it online.

i'm getting mine from Purple11haze.

me too .

I ordered mine from Lowes Saturday. They carried smaller sheets of expanded aluminum, but the 15x30 (next size up) was a special order. its $21 and they said it would take about a week.

On another note, I bought some "High Temp BBQ" paint. It says specically not to prime. Any thoughts here?

Also has anyone installed without painting? I wonder if the aluminum would look decent with a "brushed" look.

they all looke nice.... but the one with the longer corners veritcle (tolh13) looks reeaaly nice. something about it matching the grill slots. :D

I'm curious.... if any of you guys that do the mod take it wheeling in mud, let me know if there is any reduction in the mud that ends up logging the radiator. Mine is the worst I have ever seen for filling with mud. I've had a CJ5 and still own a ZJ... neither of which were as prone to mud clogs.

I pulled the splash-pan thingy under the bumper... I figure its a major contributor...

anyway... I like the mesh look. I'll be modding mine, too. ;)

Are you guy's not worried about restricting airflow into the radiator?

It looks cool but it's gonna block some air getting through and maybe alot on some of those patterns.

I've done a similar mod with my car but I cut a huge hole in the hood and put this mesh behind it for a scoop/vent.

I live in south Florida and it been i the mid to high 80s and the temp sill sits in the same place as before the mod.

Niiiice!!
 

cant wait to do it, this is something even i can do and afford to do!!!!!! seen thta billet grille for couple hundred horrible i think this is awesome......:yup:

Grill mod
 

Fulcrum, the grill probably does restrict some airflow but not enough to matter. My temp gauge i still in the same spot also. Now with that said if you go with a smaller pattern, airflow could become an issue and add more stress to your zip tie mounts. My grill has already paid for itself with absorbing some rock strikes that could have damaged the tranny cooler. Unfortunately my windshield was not so lucky.

I still have five 15"x28" sheets left if anyone is interested.

I recieved my metal from purple11haze. It was a good deal, but I haven't had tome to put it in yet.

FYI for anyone considering this - I got my metal from purple11haze, and it was in great shape... took some flat black Rustoleum nicely without any pre-sanding, and I just finished off with multiple layers of Krylon Gloss protectant... should be looking sharp when I get around to the install.

Thanks for the quick send and good material, purple!

Follow-up to the above - installation complete!

Thanks for the instruction on grill removal, OP... those little plastic "screws" :naw: would've been a huge b1tch if I didn't see your little "hint hint" comment... only nearly stripped one of 'em. Grill looks great (you'll have to take my word for now - didn't have camera handy) and was a time-well-spent mod. Hardest part of the whole thing was threading the zip ties through, and all-told, probably took about an hour (with a little of wife's help).

Love the look, and I didn't get the "grill flattening" that others described (or I did, I guess I can't tell!).

Anybody can suggest where I an find this metal sheet in Canada
 

:confused:

Send a PM to purple11haze and see if he's willing to ship to Canada.

You can try some of the larger hardware stores that sell building supplies, tools, wood...etc.

We have a couple of places here in CT, one called Home Depot, and also another one that's very similar called Lowes. These places arn't your every day little downtown hardware store, they're huge! They don't carry too much steel but you can get pieces of angle iron or steel rod in three or four foot lengths. And it's near the angle iron and steel rod where you would most likely find sheet metal, and extruded steel.
If you have any stores like that in or near your town I'm sure you will be able to find the extruded steel sheet your looking for.

Or like MJS said, "Send a PM to purple11haze" because he seems to be able to get some that's a finer or smaller mesh than what I have seen.

Got mine done. Looks great. Thanks again purple11haze for the metal.

http://my.project-jk.com/data/500/New_013.jpg

Edit to add pic.

I couldn't find it at Home Depot in Ajax but I'm pretty sure I've seen it at Rona in Scarborough.
They always seem to have a better selection than the Depot anyhow.

home depot has gutter mesh that will work.
E-bay always good.
also saw black plastic gutter cover at walmart that has round opening in it.

I went the gutter mesh from Lowe's route. I left it silver, but you could paint it any color...a lot of people are recommending Plasti-Dip paint from Lowe's to coat it.

Either way, it's a great mod, and for a noob like me, something I can do that doesn't risk messing up the whole rig if I screw up!!

Pics:

http://img46.imageshack.us/my.php?im...closeupgv7.jpg

http://img67.imageshack.us/my.php?im...installqi5.jpg

Thanks a lot guys. I will check out those hardware store first.
 

:toung: :toung: