DIY Engine Grill

[aldente295]

A little while ago I picked up a ducktail for the half dozen or so track days I do each year. It didn't come with a grill, and I wasn't really prepared to buy one for the prices I was seeing them listed at. For awhile I just had some mesh covering the hole, but then I decided to see if I could build a DIY grill out of aluminum bar. I took a few photos along the way.





















end of part 1...

[aldente295]

end of part 2...

[aldente295]

It's not gonna win any show and shine awards, but good enough for the race track!

[bigel]

How much did you end up saving?

[pksystems]

subbed.... I have something similar planned

[Elombard]

Wow - that is amazing. I wonder what it would look like with out the mesh. Just add 20 hours of tweaking grinding and polishing and it would look factory! :-)

I wonder if I could do this with L instead of U channel? Might look OK. Very creative, I love it!

[911FASCINATION]

Great work-and ability to think outside the box! Really nice to see projects that were accomplished without a lot of specialized tools and garage space-thanks for posting it!

[baloo]

very nice. good idea, and much more robust than factory.

[SilberUrS6]

Looks nice. I kinda like the mesh part. What kind of mesh is that, and where did you get it?

[baloo]

Originally Posted by SilberUrS6

Looks nice. I kinda like the mesh part. What kind of mesh is that, and where did you get it?

I think I used a similar mesh source as "aldente" -- Lowe's? Pardon the dusty tail from garage queening....
I double-folded at the front and rear edges to increase robustness -- but didn't put much effort in to alignment. I originally thought that it would not work well.

[aldente295]

Mine is actually from an old electric heater that bit the dust, but there is similar mesh at our local FLAPS here in Oz.

Probably cost me about $60 or so.

The real improvement I would love to make but don't have a solution for its getting a better curve on the flat bar. It's not quite right - the curve should be more gentle rather than two bends on either end. But I didn't have a way that I could do that easily.

I considered the L channel, and it may work - but I must say I was happy with the additional strength of the U.

[baloo]

My mesh is the 4ft x 8ft reinforcing mesh, used in plaster work or in concrete work. It's about $5 for an entire large sheet.

Since it is steel, you must spray it well to prevent rusting. I think there may be an equivalent in aluminum somewhere.

Also used it on my nose grill.

[4flyboy]

Mad skills!!!! Very inspiring....... Scott