fireplug
1/2 ton status
There was some interest in Ryoken's thread in my grill. In order to avoid a serious hijack here is some more info.
I got my idea here, http://www.off-road.com/chevy/tech/customgrill/ and used the wooden jig as well. Since I used aluminum I simply used a rubber mallet to shape the metal. I cut the metal simply using wire cutters as it is so much softer than steel. A carefully aimed angle grinder, or Dremel would work well.
Like the article I used angle to mount the grill, but again I used aluminum. Welding thin aluminum is pretty difficult and costs money if you don't do it yourself. So I used two part epoxy and formed solid sections by filling in the spaces in the expanded metal in the appropriate locations. 'Appropriate' meaning in the same areas as the factory screw holes. When the epoxy cured I drilled a hole in each section in order to attach aluminum angle to mount the grill. I attached the two using rivits, bolts would work fine too. Finally, though not really needed I filled in the seam that forms the bottom curves with the epoxy just to solidify the hole thing.
In my wonderfully executed diagram the legend is such;
BLACK = sheet of expanded metal
BLUE = folds
RED = cuts
GREEN = bends
GREY = area filled with epoxy
In the bottom corners I did a series of complicated cuts in order to make as clean a 'seam' as possible. I had assumed that this particular grill would be my trial attempt and I would do a second 'good' grill. As it turned out pretty darned good the first time I just used it. In this first attempt the cuts I made in the bottom corners are represented by the diagonal red lines. If I was to do it again I'd cut along the bold dotted red line.
I had intended to get fancier around the opening for the hood, but truth be told it's good enough. I cleaned up the cut edges with a file and it is just fine. Originally I was going to frame the opening with angle. Seemed pointless in the end.
I did this mostly for looks to be honest, I think it makes the truck look far more aggressive. However it provides a great place to put additional lighting, while protecting that lighting from rocks and theft. And I suppose it increases air flow to the rad but that is minimal at best. Aluminum was my choice because it's so easy to work with, and won't rust. I hate rust.
I'm pretty sure my directions are as clear as mud so feel free to give me a WFT
and I'll try and make it clear.
I got my idea here, http://www.off-road.com/chevy/tech/customgrill/ and used the wooden jig as well. Since I used aluminum I simply used a rubber mallet to shape the metal. I cut the metal simply using wire cutters as it is so much softer than steel. A carefully aimed angle grinder, or Dremel would work well.
Like the article I used angle to mount the grill, but again I used aluminum. Welding thin aluminum is pretty difficult and costs money if you don't do it yourself. So I used two part epoxy and formed solid sections by filling in the spaces in the expanded metal in the appropriate locations. 'Appropriate' meaning in the same areas as the factory screw holes. When the epoxy cured I drilled a hole in each section in order to attach aluminum angle to mount the grill. I attached the two using rivits, bolts would work fine too. Finally, though not really needed I filled in the seam that forms the bottom curves with the epoxy just to solidify the hole thing.
In my wonderfully executed diagram the legend is such;
BLACK = sheet of expanded metal
BLUE = folds
RED = cuts
GREEN = bends
GREY = area filled with epoxy
In the bottom corners I did a series of complicated cuts in order to make as clean a 'seam' as possible. I had assumed that this particular grill would be my trial attempt and I would do a second 'good' grill. As it turned out pretty darned good the first time I just used it. In this first attempt the cuts I made in the bottom corners are represented by the diagonal red lines. If I was to do it again I'd cut along the bold dotted red line.
I had intended to get fancier around the opening for the hood, but truth be told it's good enough. I cleaned up the cut edges with a file and it is just fine. Originally I was going to frame the opening with angle. Seemed pointless in the end.
I did this mostly for looks to be honest, I think it makes the truck look far more aggressive. However it provides a great place to put additional lighting, while protecting that lighting from rocks and theft. And I suppose it increases air flow to the rad but that is minimal at best. Aluminum was my choice because it's so easy to work with, and won't rust. I hate rust.
I'm pretty sure my directions are as clear as mud so feel free to give me a WFT
and I'll try and make it clear.
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