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TEch week - Building a custom grill

Discussion in 'The Hokey Ass Message Board' started by dabirdguy, Sep 12, 2011.

  1. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

    I wanted a custom grill for my '50 PU.
    This is what I made:

    [​IMG]

    First I bent some Stainless 1" weave to match the shape of the upper grill bar. The stainless weave will end up up inside the bar.
    [​IMG]

    Then I cut some pieces of 22 guage stainless flatstock for the mounts. I bent the 4" x4" pieces in half to start.
    [​IMG]

    To get the tabs in the right place first I positioned the piece on the grill to determine where the vertical rods crossed the piece and marked them with a magic marker.

    [​IMG]

    I used the portion where the vertical bars cross the support piece to set the height by bending them forward before I cut them off. Then I bent and fed the other tabs thru the bars, cut them to length, and bent them up around the horizontal rods.
     
  2. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

  3. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

    Then the pieces were firmly crimped around the bars and welded using my mig and stainless steel wire to avoid rusting. I won't show you my bugger welds here...LOL.
    [​IMG]

     
  4. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

    For the pieces that went on the curved sections of the grill I used a stretcher to mimic the curve of the weave.
    [​IMG]
    I made tabs for all the mounting points the grill bar uses to attach to the other sheetmetal. I did this for both top and bottom.
    [​IMG]
     

  5. Racewriter
    Joined: Nov 14, 2008
    Posts: 780

    Racewriter
    Member

    Perfectly timed, Glenn - I have been thinking about something similar myself. Thanks!

    Oh, and where did you get the stainless weave - is this a Home Depot type item, or a metal supply item?
     
  6. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

    Then I built the side pieces. They were rolled on an English wheel to match the bend of the edge of the bar and I used a break to make the bends. These pieces are 1.25" longer than the stainless weave was high. The edge that will be exposed was folded back over itself to make a clean smooth edge.
    [​IMG]

     
  7. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

    I cut the underside edge of the top bar to allow the end pieces to slide up and into the bar using a Dremel tool and a fine cutting disk. Here you can clearly see the shape the uprights need to have.
    [​IMG]
    This is how they fit together:
    [​IMG]


    I put a bar on both top and bottom, thus totally retaining the side pieces.
    For decoration I added a cast flying eyball.


    [​IMG]

    Not a bad result, eh?
    [​IMG]

    [​IMG]


    My apologies for the brevity and the crummy pictures, but I was in a hurry to get this posted before the deadline!
     
  8. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

    The weave came from a metal yard here in St. Louis. It is DEFINATELY not Home depot stuff.
     
  9. stevechaos13
    Joined: Sep 11, 2008
    Posts: 419

    stevechaos13
    Member

    Clean work man.
     
  10. Danimal
    Joined: Apr 23, 2006
    Posts: 4,130

    Danimal
    Member

    Nice work.

    I always knew you wanted a cyclops!

    (Inside joke)
     
  11. Mr48chev
    Joined: Dec 28, 2007
    Posts: 29,541

    Mr48chev
    ALLIANCE MEMBER

    Last edited: Sep 12, 2011
  12. metlmunchr
    Joined: Jan 16, 2010
    Posts: 769

    metlmunchr
    Member

    McNichols Company has a bigger variety of metals like this than anyone else in the country, and they do sell small quantities. In addition to the woven wire mesh, they also have lots of different patterns in perforated metals. Most stuff is available in copper, stainless, mild steel, and aluminum.

    http://www.mcnichols.com Pricing is on their site once you specify a material and quantity.

    Materials like these are NOT CHEAP, but you generally don't need big quantities for the typical car project, so they're a way to add some unique features without spending a ton of money overall.
     
  13. VOODOO ROD & CUSTOM
    Joined: Dec 27, 2009
    Posts: 1,240

    VOODOO ROD & CUSTOM
    Member

    VOODOO likes. Nice work. I like different.

    VR&C.
     
  14. dabirdguy
    Joined: Jun 23, 2005
    Posts: 2,404

    dabirdguy
    Member Emeritus

  15. godspeedbear
    Joined: Sep 21, 2009
    Posts: 261

    godspeedbear
    Member
    from golden

    Looks REEEAALLLL good Glenn :)
     
  16. Silverado85
    Joined: Mar 29, 2009
    Posts: 211

    Silverado85
    Member

    Man, Your truck won't look like every other 50 pickup driving down the road. Very nice Grill. Great look and unique!
     
  17. toolman1967
    Joined: Mar 13, 2008
    Posts: 441

    toolman1967
    Member

    Nice job. I like the idea of doing something different.
     

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