I decided to make the grille in three pieces, two ends and a center section. Starting off with the grille ends I took the usual steps of making a cardboard pattern and cutting it out in metal form. I then worked the metal into it new shape.
For the inside ends of the end sections I folded the end of the sheet metal to make it sifter and to give it a nicer look as it meet up with the center section. This also made it so I didn’t have to make any kind of attachment (screw, bolt, etc) between the two. Also if you look to right side of the pic you can see where I welded a small piece of a rod for a peg to hold the inside end of the section in place. This giving it a nice cleaner look with no screws.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Foldededge.jpg)
The top half of the right end section.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Endsection-top.jpg)
After the end sections were in their basic shapes I then made the center section. This one was pretty much just cutting to size and making the two bends at the top half to match the end sections. I also made so that it would lap underneath about 1” under the each end section too. I also made it so the lower half went back a 1/2". For this I cut a piece of 1” x 1/8” square tube at a length of 3/4". I then cut it in half to make two |_| shapes and welded them into place at the lower corners so that they would be behind the bumper. Next was drilling a hole through the bumper and the half square tubes. With the center section in place and using needle nose vise-grips to hold the half square pieces tight to the bumper I drilled the holes so I could thread the half square pieces for a 1/4" bolt. Then redrilled the bumper so the bolt would slide through it. I also folded the bottom edge over to stiffen it up.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Middlesectionboltconnection2.jpg)
Next I put the end sections into place and marked where I was going to bend them at so they went into the center section.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Grile-endtomiddlesetion2.jpg)
Here how it is as of now. Side view.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Endsection-end.jpg)
Front view. Sorry didn’t realize this one come out so dark. I’ll see about getting a new one before the weekend and I tear into it again.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Gille-fullveiw.jpg)
An idea of the placement of the headlights.
![](http://i223.photobucket.com/albums/dd277/Deadlypeace/Toyzilla/Body%20Work/Grille/Gille-fullveiw-lightsidea.jpg)
What’s left:
Add headlights
Cut hole for hood latch
Hide half square tube pieces
Make air way for radiator
Paint