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Old 06-12-2009, 05:46 PM   #1
2point0
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Default suggestions on DIY grill material

All these damn DIY posts are making me itch to get something done, but I've hit a snag. A while back, I took a hacksaw to my grill and love the look with no badge, but I HATE HATE HATE the crappy mesh behind it. I'm also not a big fan of spending a crapload of money on a GrillCraft. I want something I made.

Here's what I found at Lowe's the other day:
http://www.lowes.com/lowes/lkn?actio...786&lpage=none

Now, you've probably all seen stuff like this, where the flat wire is angled a bit. I don't like it. It makes a cross-section like this:
/
/
/

The one I linked is pressed completely flat and it's exactly what I wanted. Except for one small problem. It's only 24" wide and won't cover the grill! I need something 28"+ to give myself some working room, and I'll likely be installing it in front of the grill bezen, rather than behind. Not sure yet, but either way, I have to take this one back.

I've been searching all day while I work (boss is on vacation!) and just can't what I want in bigger sheets than 12x24. Also, this product was less than $10 and I have no desire to spend much more than that.

Any suggestions? Remember, I'd like to keep this CHEAP and DIY, but I'm open to new ideas...sometimes.

Thx!
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Old 06-12-2009, 06:13 PM   #2
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try mcmaster..
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Old 06-12-2009, 06:26 PM   #3
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Yea thats all i found when I was looking for some protection for my TMIC. be sure to post up if you find anything.
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Old 06-12-2009, 06:31 PM   #4
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Well, www.mcmaster.com does have a lot of different options, I am just not finding what I want cheaply. That, and I have no idea what some of those options even mean. They have the same material, flattened, but it's either 24x24 or 48x48 and then we're talking $40+. I was really hoping to find something for about the same price.

I'll be sure to post whatever I find!
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Old 06-12-2009, 06:45 PM   #5
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....I'm not sure if you can make this out that well, but here is one example of a mesh I sourced from Lowes. I beleive it's a similar material to what they make gutter gaurd from (just stiffer and comes in relatively large sheets). I had an extra grille laying around and decided to "have at it" one day. I kinda liked the look so I kept it installed:


....here's another shot further away:
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Old 06-12-2009, 06:47 PM   #6
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....btw, I painted the mesh black. It's holding up "ok" but you can notice tiny chips in the pics from road debris. I'll have to reshoot it at some point.
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Old 06-12-2009, 07:11 PM   #7
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Kean, thanks for the pic. Is that stuff pressed flat or somewhat ridged? If I can't find it flat, I think I'll get this. I saw the sheets at Lowe's/HD but wanted to hold out for the "perfect DIY grill material". Lol. Looks good painted!
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Old 06-12-2009, 08:25 PM   #8
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Old 06-12-2009, 08:30 PM   #9
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i went to lowes in the gutter dept. and they have a roll of black plastic gutter guard that iused. I had metal painted black but rocks chipped it. Its like 3.50 for a 5 ft roll
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Old 06-12-2009, 08:30 PM   #10
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Is there a DIY Grille for the new ones yet?
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Old 06-12-2009, 10:05 PM   #11
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I just returned the stuff that was too short and didn't really see anything that called out to me. I dunno, I might go back and get some thinner mesh more like what Kean posted. And I will only do this if it's metal, there's nothing wrong with the plastic mesh that's there, other than the fact that it's plastic.

I couldn't say about a DIY for newer models, though.
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Old 06-12-2009, 10:13 PM   #12
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Quote:
Originally Posted by MConte05 View Post
That looks familiar! I saw those pics while I was searching, but I'm not sure about the material. I will most likely end up with something like that at least until I find the one that was meant to be.

On a side note, I was shocked when I saw post #9! Last night I did a photochop of my blank grill but with the WRX emblem in the lower right, and this was the first time I've seen anyone who'd done it. I can't say I like having that AND the center emblem, though.
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Old 06-12-2009, 10:25 PM   #13
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Here's what I was playing around with:





Yeah, not a fan of the oval in the corner. Interesting though, and I might just tack it up there to see what it looks like in person.
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Old 06-12-2009, 10:53 PM   #14
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Quote:
Originally Posted by 2point0 View Post
Kean, thanks for the pic. Is that stuff pressed flat or somewhat ridged? If I can't find it flat, I think I'll get this. I saw the sheets at Lowe's/HD but wanted to hold out for the "perfect DIY grill material". Lol. Looks good painted!
....it's not flat. I went and pulled the roll I had to take a couple snap shots of the raw material. The first pic is of the sheet (rolled up) and the second is a close up I hope will provide you an idea of how the mesh is formed. There are several variants of expanded metal you will find:




I hope this helps.
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Old 06-12-2009, 11:05 PM   #15
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Thanks for the pic! Yup, that's the stuff I've been finding. It works, but the flat looks 130948365026% better, IMO. Ugh, maybe I'm just being way too picky about this, but I refuse to let it beat me...

Never give up. Never surrender!
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Old 06-12-2009, 11:40 PM   #16
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...I guess it's a matter of opinion. Here are some pics of a Lotus owner using what is essentially the same type of material/pattern: (http://www.sandsmuseum.com/cars/elis...hgrille.html):




Also, take a look at the following site. They may just have what you're looking for:

http://www.customcargrills.com/products.asp?id=1

You can by all sorts of different mesh in sheets. I hope this helps.

Last edited by Kean; 06-12-2009 at 11:47 PM.
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Old 06-13-2009, 12:02 AM   #17
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This stuff was just right; I used rain gutter guard mesh I got for free.

There are still two little lumps in the center; not perfect, but that's the best I could do before it would compromise the durability.
I think a pink i badge should make it look better too.
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Old 06-13-2009, 12:53 AM   #18
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Quote:
Originally Posted by Kean View Post
Also, take a look at the following site. They may just have what you're looking for:

http://www.customcargrills.com/products.asp?id=1

You can by all sorts of different mesh in sheets. I hope this helps.
Kean, you're my hero. That site is exactly what I was looking for! While I didn't want to pay quite that much, I'm stoked that they have what I wanted. It's the 2nd/3rd one down, the Diamond Extreme / XXL Flat. I am considering the powdercoat option, also. I think what I had from Lowe's was the smaller one. Powdercoating is $5 less on that one...

And don't get me wrong, I like how it turned out on yours and others. I just want to make it look like the picture in my head.

Oh, btw ... for mockup purposes, I stuck my "WRX" lettering from the trunk on a strip of 2x-sided foam tape and stuck it in the corner of the grill. ZOMFG it's amazing! Lol, looks way better than in the chop. Can't seem to find my original grill badge anywhere, but I'm positive I wouldn't like it.
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Old 06-13-2009, 12:57 AM   #19
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Smoke, I think it still looks clean even with the lumps. Looks like you smoothed the rest out pretty nicely. Might wanna pick those bugs out tho...
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Old 06-13-2009, 01:07 AM   #20
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Quote:
Originally Posted by 2point0 View Post
Kean, you're my hero. That site is exactly what I was looking for! While I didn't want to pay quite that much, I'm stoked that they have what I wanted. It's the 2nd/3rd one down, the Diamond Extreme / XXL Flat. I am considering the powdercoat option, also. I think what I had from Lowe's was the smaller one. Powdercoating is $5 less on that one...

And don't get me wrong, I like how it turned out on yours and others. I just want to make it look like the picture in my head.

Oh, btw ... for mockup purposes, I stuck my "WRX" lettering from the trunk on a strip of 2x-sided foam tape and stuck it in the corner of the grill. ZOMFG it's amazing! Lol, looks way better than in the chop. Can't seem to find my original grill badge anywhere, but I'm positive I wouldn't like it.
...glad it helped. I remembered the site from when I was trying to source material. They also have misc. grille attachment hardware, rubber edge trim, etc. Some basic stuff to really make nice DIY inserts.

I really like the woven mesh myself. ....a classic:
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Old 06-13-2009, 01:11 AM   #21
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...by the way, under "universal grille mesh", select "scrap heap". There are some odd sizes at discounted prices that you may be able to use.
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Old 06-13-2009, 01:27 PM   #22
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Saweeet. They had a scrap pice of the smaller flat diamond mesh for under $10! I bought that as well as some of the trim.

There's one thing off the list...
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Old 06-13-2009, 03:09 PM   #23
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Quote:
Originally Posted by 2point0 View Post
Saweeet. They had a scrap pice of the smaller flat diamond mesh for under $10! I bought that as well as some of the trim.

There's one thing off the list...
...cool. I hope it works out for ya. I'm tempted to get their big sample pack for $5-$6. They also provide a $5 coupon with the samples that you can put toward the purchase of a sheet if you decide to buy one.
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Old 06-13-2009, 11:51 PM   #24
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Quote:
Originally Posted by 2point0 View Post
Smoke, I think it still looks clean even with the lumps. Looks like you smoothed the rest out pretty nicely. Might wanna pick those bugs out tho...
Thanks! (Hurray a compliment! )

Out in the styx you can't help the bugs and dirt.

Good luck on your project, post pictures when you're done!
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Old 06-14-2009, 12:04 AM   #25
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If you know someone who does stucco, you'll have an endless supply! Used it to protect my front mount, but needs primer or it won't bond well.

Last edited by adamlavender; 06-14-2009 at 12:05 AM. Reason: sp.
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