3/4” HDPE Custom Grille

[Jeepish]

So I had a little time and rainy weather and decided to build my own custom grille out of HDPE (high density poly ethylene). I know there are a lot of options out there for replacement grilles, but I don’t get the same satisfaction buying something as I do building it. Basically all i used was a jigsaw, hole saw and a router.

 

[Roxasuras]

Looks very nice.

 

[Colderweather86]

That's cool AF!

 

[Togo]

Very nicely done.

 

[Campyman]

Respect

 

[Spanky]

So I had a little time and rainy weather and decided to build my own custom grille out of HDPE (high density poly ethylene). I know there are a lot of options out there for replacement grilles, but I don’t get the same satisfaction buying something as I do building it. Basically all i used was a jigsaw, hole saw and a router. View attachment 7646View attachment 7647View attachment 7648

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NICE!!!

 

[Togo]

Very impressEd by the head light detail. How did you do that?
maybe my next project.

 

[DesertRox]

Wow that turned out great! I like how you were able to use the router on the edges of the slots to mimic the original grills look! Want to make another one?

 

[Jeepish]

Very impressEd by the head light detail. How did you do that?
maybe my next project.

I’ll post a few more pictures later today but I made a plywood template, clamped it to the HDPE and then use a bushing and a straight bit on my router as a guide then adjusted the depth. As far as all the detail around the headlight bolts etc, I just traced around the old grille and cut it out with jig saw before hitting it with the router and bushing to recess it. The only reason I did it that way was so I could use the headlights to fasten the grille. You could just cut it out big enough to go around the headlights, bolt the headlights directly to the metal frame and fasten the grille with screws.

 

[Roxasuras]

Wow that turned out great! I like how you were able to use the router on the edges of the slots to mimic the original grills look! Want to make another one?

I'm interested

 

[Roxasuras]

I’ll post a few more pictures later today but I made a plywood template, clamped it to the HDPE and then use a bushing and a straight bit on my router as a guide then adjusted the depth. As far as all the detail around the headlight bolts etc, I just traced around the old grille and cut it out with jig saw before hitting it with the router and bushing to recess it. The only reason I did it that way was so I could use the headlights to fasten the grille. You could just cut it out big enough to go around the headlights, bolt the headlights directly to the metal frame and fasten the grille with screws.

Great attention to detail.

 

[Jeepish]

I’ll take a look in my shop when I get home and see how much material I’ve got. I think I have enough to make 2 more. I’ll check in with you guys later today. Thanks for the positive feedback.

 

[Roxasuras]

Sounds great!

 

[Jeepish]

The only material I have is a piece big enough to make 1 grille but with a lot of waste. I reached out to my supplier to see about getting some in 5/8” which is cheaper than the 3/4”. When I hear back I’ll let you guys know how much I could make them for.
I have to agree that using a thicker material makes for a more authentic look with the rounded slots. The texture on the material looks similar to a rhino lining and never has to be painted.. should be more durable. I put some expanded metal behind the slots on mine to catch some of the bigger bugs.

 

[Jeepish]

As with the half doors I was making, I am happy to share how I am making these and any information on suppliers etc.. I don’t mind making these for anybody who wants one but this is not how I make my living so I’m happy to help you make them for yourself.

 

[Spanky]

The more I look, the better I like it....

 

[Roxasuras]

Sheepish, I'm intrested, I sent you a PM.

 

[oldgreybull]

So I had a little time and rainy weather and decided to build my own custom grille out of HDPE (high density poly ethylene). I know there are a lot of options out there for replacement grilles, but I don’t get the same satisfaction buying something as I do building it. Basically all i used was a jigsaw, hole saw and a router. View attachment 7646View attachment 7647View attachment 7648

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Wow! I'm very impressed; you are indeed talented!
Looks great, any reason you decided to go with 6 slots?

 

[txroadkill]

Nice. And great use of non traditional materials for the build.

 

[Jeepish]

Wow! I'm very impressed; you are indeed talented!
Looks great, any reason you decided to go with 6 slots?

Thank you sir. 6 was always my number in high school sports and I already have a green 6 pool ball shifter. So I figured I’d stick with the theme and try not to offend any more Jeep folks than I already have.