I'm putting up now what I did a month and a half ago before all the panel treatment and coil covers were done. Just waited until I could complete the write up once the mesh came in. Due to COVID-19, things that used to take 2 days, now take 2 weeks. Things that were 2 weeks, now take 2 months. Let alone anything from China that used to take 2 months!
Let the cutting begin! As I was not happy with the length of the slots, I am shortening them 50mm-2" back to the stock length. I am leaving the rest of the grille longer as need that to fit my radiator size.
Gives you an idea how the sectioning is going to work. I cut along the splice lines of the original extension that I had done.
I would have preferred to section the bead along with the grille slots, but the grille mounting bracket on the back gets in the way of doing it. So cut a slot up the middle of the bead, flattened it, and then rounded the end again with a sectioned piece of pipe.
Filler piece tacked in ready for welding.
As usual I checked to make sure each part of the grille was flat after welding. Can just see it drip down a fraction at the ends of this grille bar.
Made up a dolly from some bar stock and hammered down onto the table to stretch it out.
Now nice and flat again. All of them were checked of coarse.
From the factory, one side of each grille bar is longer than the other making it flat across the back to compensate for the grille angle. As I planned to fit some mesh behind the grille, I need to take care of the fact that the factory didn't press the last bar at each end this way as well. The reason is they needed the material on the opposite side of the slot to mount the radiator cowling. Rather than just adding a thin strip, it is better to add a wide piece, fully weld it, then cut it back to the right width. This controls the welding distortion far better.
The distance above and below the slots is close to the same now, 5mm-3/16" more on the bottom. Not the look I intend to keep though.
I can now adjust the height of the gravel tray until I like the proportions.
Think it is looking closer to the 48 grille above it rather than the 58 grille it started out as, which is what I wanted. Remember it is 2" taller and 9" wider overall with 2 extra slots added to make it the same number as the 48 grille.
A shot showing the various Jeep grille proportions through the years. Think I am closer now with the modifications but wont know until I have the Willys back together again.
The Jeep
Trailhawk
