jes0420

I have been looking around for grille designs, and ran across a raptor style ovelrlay. I loved the look. I then looked over at the massive pile of scrap metal I have at work. So here is a little write up on how I made a new grille out of expanded metal, and a raptor overlay out of 3/16 steel.

jes0420

I started by mocking up my letters on some cardboard. Then I cut out the original H-bar grille. And test fitting my cardboard. Cutting out the grille sucked, I used an angle grinder, and a hack saw mostly.

jes0420

Drawing out my overlay on the sheet. Then rough cutting the overlay, an my expanded metal.

jes0420

Drove out to work for some sandblasting and finer cutting. I ended up using a jigsaw with a hacksaw blade for most of the cutting, then used a die grinder with a cut off wheel and a carbide bur for the rest.

jes0420

Even finer cutting, sanding, priming, painting and installing. All in all, it went pretty well. Cutting was a B!TCH. The expanded metal grille will probably need replaced, I ended up undercutting it a little so it didnt fit perfectly, I attatched it with JB putty, and some home made brackets.

JMiracle

any close up pics?

jes0420

Its not perfect, but its close, and it cost me about 3 cut off wheels.

jes0420

In the process of cutting.

Rayjht

It's actually not bad good work!

WhyteLobo07

nice!!!! It looks pretty damn good!