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.
