Before you read this and jump to a ricey conclusion, please note that the grille mesh will be painted BLACK!!!!
I was finally able to make some progress on this thing. I've read most (if not all) of the previous DIY grille threads, and almost everyone attached the mesh to the back of the grille with hot glue or liquid nails or something gooey. When I noticed an existing channel running behind the top of the bumper, a light bulb went off above my noggin, and I decided to try something new...I wanted the mesh to attach behind the grille and remain completely separate from the grille itself.
I got my Gutter Guard mesh from Home Depot - see below
Then I made some rough measurements, and trimmed the mesh with tin snips. The mesh has a natural curviture to it, which sort of works to my advantage in this case.
After a couple trial-and-error fitments and additional trimming, here's what I ended up with
Here is where I trimmed around the clips where the lower portion of the grille attaches to the headlight
And a little extra trim around the hood latch
And here is the hacked up grille clipped in place. Seems to fit really well!
Next step was to apply the first coat of paint to the mesh. As you can see, I used generic flat black auto paint from Advance Auto - nothing fancy required
Pizza box FTW!!!
Next steps are to:
1) Finish painting the mesh black
2) Apply body filler beneath the badge and sand the entire grill smooth
3) Prime the grille for paint
4) Paint the grille WRB
5) Hopefully revel in my success