How to: Grille Inserts
Estimated time: 2 hrs
This "How to" will teach you how to create your own grille inserts. Many have seen what I've done for my truck and asked where they could get some grille inserts like mine, which has ended up in my making a few sets for some members.
The method I have used to create my inserts is quite easy and can work on many different vehicles. I have found that it is easiest for the 2004-2005 Ford Rangers, because the grilles are realativly flat which is great for making templates.
Tools/materials you will need:
Vehicle with grille
Material for the grille (I used 14"x48" mesh)
1 roll of 2" wide blue painter's tape
...or Dremel tool (preferred) w/cut off wheel and sanding band
1 razor knife
Mounting materials for inserts
1. Creating the template
A. Apply 1 layer of blue tape over the area where you want your insert.
B. Cut off excess tape with razor knife.
C. Repeat steps 1-2 twice, so that you have 3 layers of tape.
D. Peel off template
2. Creating the inserts
A. Place the template on the material for the inserts.
Note: in the event of multiple inserts, work on one insert at a time.
B. Make sure the template is straight on the mesh, then press it down
so it sticks.
C. Use your tin snips or Dremel cut off wheel to cut the inserts out of
the material along the edges of the template.
D. Grind off the burs from cutting with the Dremel sanding band.
E. Test fit the insert(s) and grind off material where necessary.
3. Mounting the inserts
Editor's note: For each vehicle, mounting the inserts may be different.
Since I created the inserts for my 04 Ranger, the steps will be for that.
A. Remove the top bolts from the grille shell.
B. Hold one insert on the plastic honey comb of the grille, then secure
insert with black zip tie.
C. Repeat step B until satisfied the insert is secure. I used 3 for the
side inserts, and 8 for the center insert.
D. Cut off the ends of the zip ties.
E. Remove all tools/materials that may be on/in/around the truck.
(I ended up driving around with a pack of zip ties in my engine
compartment for 2 months before I noticed.)