This how-to shows how to make a custom grill out of wire mesh, to replace the stock grill. The how-to was performed on a Phase I Z24, but the same would apply to a Phase II model, non-Z's, or Sunbirds.
- Mesh (aka Gutter Screening)
- J.B. Weld
- Primer & Paint (Maybe Clear Coat)
- Grill (You may want to go to the Junkyard first)
- Tin Snips
- Pliers
- Dremel
Step 1
Dremel out the inside to your grill, leaving only the outer shell using a bit like the one pictured.
Step 2
Use tin snips to cut the gutter screening. You have to make the screening bigger than the grill.
Step 3
Now fold the top and bottoms to a 90 degree angle or so so it will fit from the back side of the grill and get it flush with the front. Cut the sides at an angle so it will fit.
Step 4
Now the tops and bottom, since you cut it bigger, you should just be able to fold it over the edges inside the grill, I used some pliers just to make sure it was holding on the edges.
Step 5
I used JB Weld to hold the mesh in, and let it set for 24 hours then painted it the next day.
Step 6
Put it back on the car and take a lap making sure everyone sees it ;)
