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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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#113 ·
Re: How to: Mesh grill on a 08 WK

if you dont paint it, it will rust, there was a sheet in lowes that was alittle rusty, you would atleast have to clear it, or maybe silver, depends what look you are going for, but either would look good, is your grill chome or black?
 
#114 ·
Re: How to: Mesh grill on a 08 WK

if you dont paint it, it will rust, there was a sheet in lowes that was alittle rusty, you would atleast have to clear it, or maybe silver, depends what look you are going for, but either would look good, is your grill chome or black?
Mine is Chrome, but I plan on doing black mesh. OD' on the chrome if I dont do black.

BPOD has a black grill.
 
#116 ·
Re: How to: Mesh grill on a 08 WK

Yeah true with the tapping screws. I'm going to go back to lowes tonight and get reg screws. What size did you get rufdod?

---------- Post added at 12:56 PM ---------- Previous post was at 12:55 PM ----------

Yeah Irf. Your brilliant black with the black grill it may get lost in there. I would try a silver/grey/charcoal color maybe and clear coat it...
 
#120 ·
Re: How to: Mesh grill on a 08 WK

i think a charcoal or grey would look nasty
Nasty in a good way or bad way??? LOL

---------- Post added at 01:01 PM ---------- Previous post was at 01:00 PM ----------

Maybe a rainbow? Each window a different color... LMAO
 
#122 ·
Re: How to: Mesh grill on a 08 WK

LOL You know it. I wish I could do the rainbow grill and put it on Joe's jeep when he's not looking. LMFAO!!!
 
#124 ·
Re: How to: Mesh grill on a 08 WK

Nate - 3/4" screws will be way too long IMO...I used 3/8" and they were perfect. Pre-drill your holes and do not use self-tapping screws; I do not think you get as nice of a tight fit with self-tappers.

Irf - tough decision on the color to paint it...do you have any other colors on your truck? Either go "stainless look" or gloss balck IMHO

I like that stuff from Lowes...I will prolly leave my grill on the way I have it and maybe do that later on down the road...
 
#125 ·
Re: How to: Mesh grill on a 08 WK

OK Thanks Brad. I'll get the 3/8".
 
#129 ·
Re: How to: Mesh grill on a 08 WK

Yeah go with gloss black!!!
 
#133 ·
Re: How to: Mesh grill on a 08 WK

nope ha, but it is sharp, im in the process of doing the srt conversion, id like to use this stuff in the lower grill but i dont know if ill be able to find any longer, and if not i dont think i could make it look right by splicing 2 pieces to fit the whole bumper, there is no where to hide it.
 
#135 ·
Re: How to: Mesh grill on a 08 WK

^^^ i looked into that... the thickness is actually the same as the one nate got from lowes.. its actually the same mesh except its powdercoated

---------- Post added at 01:13 PM ---------- Previous post was at 01:11 PM ----------

i was considering this one though in gloss black:)
 
#138 ·
Re: How to: Mesh grill on a 08 WK

theres another site i was thinking of....but zi cant find it at the moment. Robpp bought some mesh from them....maybe he will chime in
 
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