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How To: Install a mesh grill on a 08 WK

131K views 472 replies 61 participants last post by  08Hemi 
#1 · (Edited)
So I went to Home Depot today and had to make myself a grill:D! I will show you what I did and feel free to comment or ask anything...

I bought:

Rustoleum Gloss Black Spray paint
Rustoleum Lacquer (clear)
16 3/8 in #6 or #8 head screws
16 #8 or #10 head washers
1 Aluminum sheet (cross-hatched)

Tools:

Flat head screw driver
Phillips head screw driver
Power drill with small taping bit (half of screw)
Plastic Cutters
Wire/sheet metal cutters
Metal file for rough edges


1. First take off the grill. There are 6 push clips that are holding the grill in. Use the FH screwdriver to pop these off. Very simple

2. Put the grill face down on a towel or something soft. Cut out all plastic pieces and tabs. You want the grill to sit as flush with the back as possible, so trim the tabs well.

3. Cut a piece out of aluminum foil that is the entire size of the back of the grill. I error'd on the side of larger to ensure I could trim as needed. This really helped later so I recommend doing this. I painted it gloss black; it looks great and is subtle so I am happy with the chrome-gloss black contrast!

4. Test fit the aluminum. I cut around the four tabs on the bottom of the plastic and the center of the plastic piece, also around the edges and any area raising the aluminum up. I also cut slats in the aluminum for the 4 chrome plastic tabs that stick out. I did not want to cut those off so you can do whatever you want here.

5. Make sure the grill is set and fits properly all the way around. Take your time; I spent over 15 mins trimming the aluminum around the back of the grill!

6. Pre-drill your 16 mounting locations on the top and bottom of the grill. Make sure it is where you want it. I chose 16 screws but you could probably get away with less. I did mine in the same general locations on the top and bottom so it looks really clean and holds the grill firmly in place.

7. Put the washer in-between the aluminium and the screw, tighten them down starting from the middle and working outward. Tighten hand-tight ( I used a drill but it does not need much force)...the aluminum will set with the washer.

8. Fit the grill back onto the car and insert the 6 push pins starting with the center and working outwards.

9. Drive around for 10-20 miles or so. Take the grill back off and tighten all of the screws. All of mine needed a little tighten as I think the grill settled in a little bit. Needless to say it is very tight on there and is actually one with the stock chrome grill (for all intents and purposes it is one piece :) )! Now put it back on and the 6 push pins back in....

You are all done...you now have a grill!

















So what do you think? Not bad for about $20 in products and about 2 hours total including paint drying and test fitting...:thumbsup:
 
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#3 · (Edited)
Re: How to: Mesh grill on a 08 WK

Thank you...yeah I have always wanted to paint the side chrome moldings and my grill white. I need to save up for that!!! Here is another finished pic...I will take more tomorrow in the daylight. I finished in the dark haha


and here is a before pic...



After


More after pics in the daylight...







 
#4 ·
Re: How to: Mesh grill on a 08 WK

Nice job Brad. You just inspired me to do something like that too. LOL :thumbsup:
 
#5 ·
Re: How to: Mesh grill on a 08 WK

self made stuff's the best! looks good brad. prolly do something like that also
 
#7 ·
Re: How to: Mesh grill on a 08 WK

Looks good. I shoulda taken pics when I did mine.
 
#10 ·
Re: How to: Mesh grill on a 08 WK

coolio. who wants a 07 black grill. ill have one soon, nate?
What chu talkin bout??? Lets do it shorty. Does anyone have a white grill? Only white WK's Ive seen are limited's.
 
#13 · (Edited)
Re: How to: Mesh grill on a 08 WK

Thanks Davy Nate Scott and klutch! It is super simple to do and if you take your time it turns out very nice. Anybody that has 20 bucks lying around, a couple hours and a stock grill should do this. It is will save your radiator a little too! Thanks for the rep Frankie!
 
#20 ·
Re: How to: Mesh grill on a 08 WK

I painted both sides with 2 coats on each side...I wanted more paint on there than not and I had good weather so I figured more was better...I just let it dry on the cardboard for 20 mins, flipped it and painted, let sit for 20 mins and did both sides one more time

I cut another piece the exact same size as the one I pre-fitted so if something happens to this one (ie paint comes off or huge dent) I can take it off, paint it and add the other one I made. I had a lot of aluminum left over so you could prolly make a couple "back-ups"
 
#21 ·
Re: How to: Mesh grill on a 08 WK

what size mesh did you buy? i want to go to homedepot today to get the stuff!!!

did you use galvanized screws so they don't rust?

since you clipped off the tabs i'm guessing the stock insert cannot be put back on correct?

i also have an 08 do you have the dimensions?
 
#22 ·
Re: How to: Mesh grill on a 08 WK

I believe it was 3/8" aluminum sheeting...it was the only kind they had at Home Depot; it was in the wood section near fencing and fencing posts.

I did not buy special screws...they are just basic 3/8" #6 headed screws. I wanted to keep the costs down so I bought the smallest and cheapest I could find. My thought was if i need to replace the grill I can use a larger and higher quality screw later on I could. I also live in Cali and garage my ride so hopefully I won't have to worry about the rust :)

Take a look at your grill and you will see that the stock inserts are useless after you cut them out. You could probably jerry-rig something and put them back in, but trust me you will not want to after you get them out!

I can give you the dimensions (they are at home)...BUT read my first post. I spent over 15 mins trimming down the piece to fit properly, so actual measurements are not really going to work properly. Cut it out so it covers the ENTIRE back of the grill, cut slots for the tabs and trim around the edges to ensure perfect fitment! Hope that helps
 
#26 · (Edited)
Re: How to: Mesh grill on a 08 WK

So I pulled the grill off today after work and took a couple more pics on and off the Jeep. One thing I had to do was tighten all 16 of the bolts; the grill settled after 15 or so miles and being added back to the Jeep. There was a little trimming I did for a more flush fit against the grill, and after I did this there was play in all of the screws. I tightened them all and now the mesh is one with the grill! FYI this is a must step that I will add to the original write-up!
 
#27 ·
Re: How to: Mesh grill on a 08 WK

hey brad the truck looks badass!!!!! i bet i know a fellow stonewhite owner will be doing this asap! i got my hids up and running today so i am gonna go to home depot tom to buy this stuff!!! looks great bro! good work and thanks for the new pics:)
 
#28 ·
Re: How to: Mesh grill on a 08 WK

If I'm ever in SB I'll be keeping an eye out for that fresh grille of yours..:thumbsup:
 
#29 ·
Re: How to: Mesh grill on a 08 WK

Brad, Why does your grill look like black chrome in some pics? LOL I was like :eek: Where the f*ck did he get that grill from. LMAO That would look sexy with some matching black chrome 22" vipers.
 
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