Similar to what others have done:

I used hexagonal perforated aluminum sheet metal, from Grainger or McMaster Carr (36x48" about $38), primered and painted black.

Rather than tying with zip-ties to back of the grille, I simply formed the sheet metal with Z-folds at top and bottom, and notched out along the bottom for the clips, and ambient sensor, and along the top for the wire bundles, etc.

I did re-route the top wire bundle under the frame rail to allow the mesh to sit flatter against the frame. Once the mesh is positioned and you re-install the grille, it stays in its proper position.

I cut a sheet exactly 27"x17" and made the folds as marked on the sketch, which worked out pretty well; there is a slight bow in the Jeep grille piece so if you want a snugger/more tapered fit from the mesh you can adjust the folds accordingly. I used a rolling pin to slightly form a curve to the mesh prior to positioning it in front of the frame rails.

Thanks to another forum member for the sketch/dimensions, which he used for a template...I don't think he'll mind if I post it here!

The sketch doesn't include all the notches mentioned but you'll figure it out!

 

That looks really good, I may try this when my Jeep arrives. Thanks for posting the sketch also.

 

Thats nice - I love McMaster-Carr so I might try this...

Thanks

BR