Grill Mod
JK Enthusiast
Joined: Jan 2008
Posts: 358
Likes: 0
From: Sarasota, Florida
[QUOTE=brattwurzt;328333]While thinking about this grill mod, I came up with a different approach. I will admit that I spent a bit much, because I went with stainless, but I wanted it to be maintenance free. Basically, instead of attaching the screen to the plastic grill (no glue guns or zip tie blocks), I fashioned the screen to fit the radiator housing.
Step 4:
I fit it into place:
I did not even have to fasten the screen to the radiator surround. The plastic grill holds it in place. In other words, no mods to the actual jeep. No holes drilled.
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Just a question about this- does it restrict airflow being right up against the radiator rather than pushed more towards the grill?
Step 4:
I fit it into place:
I did not even have to fasten the screen to the radiator surround. The plastic grill holds it in place. In other words, no mods to the actual jeep. No holes drilled.
-------------------------
Just a question about this- does it restrict airflow being right up against the radiator rather than pushed more towards the grill?
Last edited by DKJeep17; Apr 19, 2008 at 06:53 AM.
JK Newbie
Joined: Feb 2008
Posts: 85
Likes: 0
From: Tacoma, Washington, United States
I got mine at Lowe's, and it was maybe 2 feet from where the metal gutter guard stuff was that I bought the day before. It comes in a roll. I found it on aisle 19, with the rest of the gutter stuff (some lowe's are numbered the same, some aren't). Unfortunately, I don't have the original wrapper anymore, because it is tied up in my garbage can. However, I do have about 15 feet left, so if you can't find it, PM me and I will mail you the rest. In actuality, that would probably cost close to what it was at the store though, so you'll want to find it where you are.
It does not exist at Home Depot here, I went there first, even though I had seen it at Lowe's the day before.
Here is what it looks like
It does not exist at Home Depot here, I went there first, even though I had seen it at Lowe's the day before.
Here is what it looks like
Took about 2 1/2 hours...Not counting the hour plus to clean off the work bench.
I Peeled off the self adhesive stuff and used 2 part epoxy made for Plastic.
JK Newbie
Joined: Feb 2008
Posts: 85
Likes: 0
From: Tacoma, Washington, United States
I am guessing that there is less than 5% airflow restriction because of the mesh. Although I have not taken out my micrometer and slide rule to verify that number.
Some of the aftermarket grill inserts appear to be closer to 50% airflow restriction (Vertical Billet Inserts).
The only airflow issue I can think of is getting the mesh clogged with suicidal bugs. But it appears that they would clog the radiator just as well. Might even be easier to clean off of the mesh than the radiator.
(The opinions of the author of this message are merely a WAG {Wild Assed Guess} and not the more official interpretation SWAG {Scientific Wild Assed Guess} that would have required some form of mathematical computation.)
JK Enthusiast
Joined: Mar 2007
Posts: 253
Likes: 0
From: The "ROK" (originally from SoCal)
Hi guys...
I'm dieing to do this mod and am trying to buy the materials online. I've gotten myself completely confused on the McMaster-Carr web site....There is just WAY too many options to chose from once you find the "expanded aluminium sheet". Plus, from what I see, it only comes in sheets of 24''X24'' (which is to small to do the mod), and 48''X48" which is too big to ship..to where I am anyway. What I need is an exact part # to the right sheet to buy. I've gone through this entire thread and cant seem to find it. I know, I probably missed it, but I looked hard, there's only like 29 pages to this baby...lol
Thx for any help,
Tony
I'm dieing to do this mod and am trying to buy the materials online. I've gotten myself completely confused on the McMaster-Carr web site....There is just WAY too many options to chose from once you find the "expanded aluminium sheet". Plus, from what I see, it only comes in sheets of 24''X24'' (which is to small to do the mod), and 48''X48" which is too big to ship..to where I am anyway. What I need is an exact part # to the right sheet to buy. I've gone through this entire thread and cant seem to find it. I know, I probably missed it, but I looked hard, there's only like 29 pages to this baby...lol
Thx for any help,
Tony
JK Enthusiast
Joined: Jan 2008
Posts: 358
Likes: 0
From: Sarasota, Florida
Hey man- If you've got a Home Depot close, go there and spend all of $25.00 for the whole thing!! (And no shipping!)
Building materials has gutter guard
Electrical has zip ties and zip tie blocks
Tools has some wire cutters (if you dont have any already)
and grab some guerilla glue anywhere ya see some (for the permanent aspect of the mod)
Good luck!!
Building materials has gutter guard
Electrical has zip ties and zip tie blocks
Tools has some wire cutters (if you dont have any already)
and grab some guerilla glue anywhere ya see some (for the permanent aspect of the mod)
Good luck!!
JK Newbie
Joined: Oct 2007
Posts: 16
Likes: 0
From: Georgia
I looked for the aluminum mesh at Home Depot and Ace hardware but could not find any. I came across this plastic/vinyl gutter block (comes in 3' sections) and cut it to size then painted it metalic silver which closely matches the paint on my Sahara. Time will tell if the painted plastic stands up to the elements but then again everything else on the Jeep is painted plastic 
What was your method of attaching? Zip ties and blocks?
What silver metallic paint did you use?
Thanks
JK Super Freak
Joined: Jan 2008
Posts: 1,835
Likes: 0
From: The Deep Dark Woods of Texas!
While thinking about this grill mod, I came up with a different approach. I will admit that I spent a bit much, because I went with stainless, but I wanted it to be maintenance free. Basically, instead of attaching the screen to the plastic grill (no glue guns or zip tie blocks), I fashioned the screen to fit the radiator housing.
Step 1:
I made a cardboard template.
The template took some fitting.
Step 2:
I cut the screen to match the template:
This part is a bit tricky, and the stainless I bought was kind of thick, however, I was able to cut it with a sheet metal cutter.
Step 3:
I then bent the screen to match the template:
Step 4:
I fit it into place:
I did not even have to fasten the screen to the radiator surround. The plastic grill holds it in place. In other words, no mods to the actual jeep. No holes drilled.
Step 5:
Replace the plastic grill:
This whole mod took about 1 hr. The best part is because there are no actual mods to the jeep, I can easily just remove it.
By placing the screen onto the radiator surround, it provides a very strong and ridged barrier. The fit is tight against the plastic grill.
Edit: 04/08/2008
Many people have asked me for the template. Unfortunately I sent the master template (the actual cardboard template) to Cross007, but I do have the original drawing of the basic template. This is just the basic version, and I would recommend following this to make a cardboard template that you can fit and trim to fit. I have included the very basic dimensions and cut outs. This is all I have.
Step 1:
I made a cardboard template.
The template took some fitting.
Step 2:
I cut the screen to match the template:
This part is a bit tricky, and the stainless I bought was kind of thick, however, I was able to cut it with a sheet metal cutter.
Step 3:
I then bent the screen to match the template:
Step 4:
I fit it into place:
I did not even have to fasten the screen to the radiator surround. The plastic grill holds it in place. In other words, no mods to the actual jeep. No holes drilled.
Step 5:
Replace the plastic grill:
This whole mod took about 1 hr. The best part is because there are no actual mods to the jeep, I can easily just remove it.
By placing the screen onto the radiator surround, it provides a very strong and ridged barrier. The fit is tight against the plastic grill.
Edit: 04/08/2008
Many people have asked me for the template. Unfortunately I sent the master template (the actual cardboard template) to Cross007, but I do have the original drawing of the basic template. This is just the basic version, and I would recommend following this to make a cardboard template that you can fit and trim to fit. I have included the very basic dimensions and cut outs. This is all I have.