Grill mod with CAD and 3d printer
 

yep another grill mod thread...This one was done using 3d cad and a 3d printer. I wanted to come up with a solution that would allow me to use screws instead of the sticky clips and zip ties. I wanted to make sure that the gutter guard was flat to the inside of the grill as possible.

i started by modeling the cross section of the grill and then modeling a block that could be glued into place.
Attachment 450226
Then i printed around 48 of the blocks using a Fused Deposition Modeling (dimesion) machine. Once i had the blocks I used tape to align the locations then i started glueing them in using a 2 part epoxy.
Attachment 450227
Attachment 450228\
Attachment 450229
I ended up cutting the blocks in half for the location on the top of the grill holes since there was a hose that was in the way.

Once i had the blocks glued down, i used the gutter guard stuff that i purchases from lowes. I primed and painted them with some flat black crylon paint. Then i used some wood screws and some finishing washers to hold them on location.
Attachment 450230
I ended up using some of the stick down zip tie things along the bottom of the openings just to make sure they didnt flex out on the bottom.

The results
 

It took more time than I have read that it took others but I am happy with the results.
Attachment 450231
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Looks good! Really clean, I like the block idea. Way better than the blocks and zip ties I used.

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wanna send me the printer design file ?

I can send out creo-2 files, step, iges, stl... pm me if'n you want a copy

looks pretty good!