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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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#191 ·
Re: How to: Mesh grill on a 08 WK

That looks grreat, I can't wait to do mine this weekend.

Ben
 
#193 ·
Re: How to: Mesh grill on a 08 WK

Thats badass. I dont think i got the craftsmanship to pull something this simple off lol
 
#195 ·
Re: How to: Mesh grill on a 08 WK

Maybe but your talkin to the guy who put antifreeze where the windshiled wiper fluid should go. . . lol
 
#197 ·
Re: How to: Mesh grill on a 08 WK

Never used one. Im sure i can get some help around here tho.
 
#199 ·
Re: How to: Mesh grill on a 08 WK

Yeah ill see if i do this on the weekend. It'll be the first mod on my jeep.
 
#201 ·
Took the grill off this weekend and re-sprayed with gloss black and clear'd it. IDK why I didn't clear the top like I did the bottom, but the paint was comming off and I had to do something. Put like 3 coats of gloss black, waited 24 hours then 3 coats of clear on so I should be good to go for at least a couple months?
 
#204 ·
You mean the clone of my grill... LOL J/K But I keep forgetting I have to get my grill from ya Irf. I guess cause with all this sh*ty weather I haven't washed the jeep in like 5 weeks so It's on the back burner...
 
#206 ·
Yeah And I haven't waxed her since I got her.
 
#208 ·
Yeah I know... Shame on me
 
#209 ·
Funny I just read this, I primed and painted a piece of mesh gutter screening they sell at the Depot to install in the lower bumper. I think its aluminum. I used a can of cheap indoor/outdoor equipment grey primer with two coats of Rustoleum flat black(all that was left in the can) then a whole can of Krylon indoor/outdoor semi gloss black last night. Wonder if I should clear coat it, but I dont want it shiney, I want it dull like the srt plastic mesh in the grill. They way the mesh is shaped its curved length wise, so when I straighten it out its bowed and think I can get away with just useing zip ties at the outer edges and it would press in there nice. Will try it in a bit, just got home from work.
 
#215 ·
I just went out and looked. Maybe its because I have a black car so the mesh doesnt look as shiney to me against the surrounding black trim. Its def not shiney like the cars finish and there are dull areas prob from hitting it with a sponge washing it all the time. The semi gloss mesh I just painted matches it great IMO.
 
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