Grill Mod
04-05-2008 | 05:37 PM
#261
JK Freak
Joined: Mar 2007
Posts: 517
Likes: 1
From: Prescott Valley, AZ.
I looked for the aluminum mesh at Home Depot and Ace hardware but could not find any. I came across this plastic/vinyl gutter block (comes in 3' sections) and cut it to size then painted it metalic silver which closely matches the paint on my Sahara. Time will tell if the painted plastic stands up to the elements but then again everything else on the Jeep is painted plastic 
That looks Great. Where did you find the palstic?
04-05-2008 | 05:39 PM
#262
JK Freak
Joined: Mar 2007
Posts: 517
Likes: 1
From: Prescott Valley, AZ.
For those who are having issues with the blocks coming off:
I, too used epoxy on the blocks after they were stuck on around the edges and over the flat part of the block. It looks sloppy (because I epoxied in excess) but the "overkill" will help it hold. I first prepped the grille by sanding it lightly and then cleaning everything up with alcohol. I used more blocks than others here because i figured if I had it off already, then I may as well do the job so I didn't have to do it again.
I live in Ohio. I put the mesh on at the end of August and there is no sign of it loosening. We'll see after it gets really hot this summer. I think it'll be OK, though.
I, too used epoxy on the blocks after they were stuck on around the edges and over the flat part of the block. It looks sloppy (because I epoxied in excess) but the "overkill" will help it hold. I first prepped the grille by sanding it lightly and then cleaning everything up with alcohol. I used more blocks than others here because i figured if I had it off already, then I may as well do the job so I didn't have to do it again.
I live in Ohio. I put the mesh on at the end of August and there is no sign of it loosening. We'll see after it gets really hot this summer. I think it'll be OK, though.
04-05-2008 | 06:01 PM
#263
JK Enthusiast
Joined: Mar 2008
Posts: 159
Likes: 1
From: NH
It was in the gutter section and it was all they had at my local Ace hardware for gutter block material. Frost King White Vinyl Snap in gutter screen model G636W.
I hope the paint holds up - the metallic silver spray paint looks factory...
I hope the paint holds up - the metallic silver spray paint looks factory...
04-08-2008 | 11:43 AM
#264
JK Enthusiast
Joined: Jun 2007
Posts: 259
Likes: 0
From: Baltimore, MD
Basic Grill Template
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.
04-08-2008 | 09:52 PM
#265
JK Super Freak
Joined: Oct 2007
Posts: 1,476
Likes: 0
From: Jackson Hole, Wyoming
We bought some 1/2 inch expanded metal at Lowe's for only $5.97. The grill mod was done today and we are very pleased with how it looks. Thank you all for the great thread with all the hints and ideas. It made the job a snap! A special thank you for the great pictures posted and for the wonderful template that worked like a charm. 
04-09-2008 | 07:57 AM
#266
JK Enthusiast
Joined: Dec 2007
Posts: 381
Likes: 0
From: Pittsburgh, PA
i'd love to see a pic. mine is already done, but a friend of mine has a JK on order and wants me to do his.
i used the screen door protector from lowe's and i think it looks great, but at 6 bucks.......your material is about $16 cheaper.
....not that $22 would break the bank, but why not save a few bucks if you can?
how about the rusting issue? mine is aluminum and i expect it to hold up well.
..................OR we could just buy the inserts for $289!
i've seen some on ebay for $329! 
i used the screen door protector from lowe's and i think it looks great, but at 6 bucks.......your material is about $16 cheaper.
....not that $22 would break the bank, but why not save a few bucks if you can?
how about the rusting issue? mine is aluminum and i expect it to hold up well.
..................OR we could just buy the inserts for $289!
i've seen some on ebay for $329!
04-10-2008 | 09:28 PM
#268
JK Super Freak
Joined: Oct 2007
Posts: 1,476
Likes: 0
From: Jackson Hole, Wyoming
We bought some 1/2 inch expanded metal at Lowe's for only $5.97. The grill mod was done today and we are very pleased with how it looks. Thank you all for the great thread with all the hints and ideas. It made the job a snap! A special thank you for the great pictures posted and for the wonderful template that worked like a charm.
04-11-2008 | 05:57 PM
#270
JK Enthusiast
Joined: Mar 2008
Posts: 202
Likes: 0
From: Biloxi, MS
I did mine yesterday and used the basic template. I was walking around the hardware store looking for some mesh. Looked over and saw some stucco mesh. Called up my brother-in-law (works construction) to see if he had any they were not gonna use. He brought me a sheet home. They cost like $7 per sheet and are like 8 feet long and 27 inches wide, so you have extra materials if you mess up. The template helped me greatly. Very easy and took like 1 hour to complete.