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After seeing CJs grill minus a few bars I knew I had to have this mod. All it really takes is a socket to unbolt the grill, a few screwdrivers, pliers for shaping the gutter mesh, and most importanly a dremel tool.
Start by remove the grill and unbolt the upper and lower black braces and the center support rod. Find a comforable place to work and put a cutting wheel on the dremel. The first cuts are rough to remove the bars above and below the bowtie. Don't worry about how these cuts look, they will be cleaned up later. Just use two hands on the dremel so you dont cut anything that's going to stay. You may flip the grill over and make some cuts from the back if needed. Heres what the rough cuts look like.
Next, switch to a smooth grinding wheel on the dremel.
Now, take your time, clamp down the grill so it doesn't move or have someone help you hold it. You want to keep both hands on the dremel for your finish work. As the plastic heats up it cuts/grinds away faster. Just slow down around the edges you want to keep.
This is where the vertiacal supports were ground smooth
This one shows about half of the grinding complete on the bowtie. As you are finishing up the grinding angle the dremel back to reduce the exposed white plastic. You wont see much of the white platic at all when done. Any left exposed can be touched up with a dab of paint if needed.,
and the sides
Heres everything all cleaned up
Now for the screen.
Start with the top. Use your pliers and bend about 1/4" down around the top edge. then mark the screen against the grill and cut. Once cut, bend the sides to match the top edge.
You'll need to make holes for the tabs
Bottom screen is next, make the same 1/4" bend at the bottom. Mark and cut. Make holes for the screw attachements. Bend the sides to fit.
Now fit the screens. Top first, then the bottom. Take your time to align the edges, trim as needed to fit.
Reinstall the braces, bottom first, then top and then center bar. Keep checking for fit, make adjustments to the edge bends and cut any excess that is causing fit problems.
Here's the finished assembly.
and back on the car..
This is not a hard thing to do, just takes a dremel and some patience. Thanks for your help with this CJ. 
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Still playing in the streets
Last edited by TX-HHR on Sat Nov 24, 2007 4:55 pm; edited 2 times in total |
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