How to Make Your Own Truck Grill
- 1). Make a template for the grill using cardboard and a utility knife. You can make the template to fit the grill opening or lay the existing grill on the cardboard and trace the outline with the knife. A template ensures you fabricate the grill to the correct dimensions and have correct locations for any lights.
- 2). Place the grill material on a worktable or workbench. If you are making a grill with sections of tubing or chrome strips, space the pieces according to your design.
- 3). Position the template atop the material. Transfer the outline of the template onto the material using a felt tip marker. Use a yellow or white marker for outlining darker material.
- 4). Cut the mesh or individual pieces with a variable-speed electric jigsaw and a finish blade. Use the slowest speed possible to prevent the edges of mesh from chattering as you make the cuts.
- 5). Smooth the cuts with a flat file. File downward from the finished side of the material using light strokes. Avoid filing upward along the edges or you may ruin the finish.
- 6). Position the grill in place on the truck. Mark any areas or sections that need to be detailed to ensure a tidy fit. Mark the locations of attachment bolts or clips.
- 7). Detail the grill as needed using the flat file. Drill the holes for the attachment bolts or clips using an electric drill and the appropriate size drill bit.
