Jeeps have large gaps in their grills, which aids in cooling, but leaves the radiator vunerable to rocks
and other impact damage. Thereare a ton of various "grill" guards on the market, but each one I've seen
goes outside the grill. I feel this detracts from the rugged looks of a jeep. I decided to build my own.
The final product is the result of collaboration between my father and I.
What it looks like
This is what the finished product looks like. It's simple, but when done does require repainting the grill.
The materials list is pretty short: this is for a CJ5 or CJ7--other models will vary!
1-18"x 18" (approx) piece of expanded metal
6-1/4"x 3" Carriage bolts (or longer depending on your grommets
24-1/4" Flat Washers
12-Rubber Grommets with approx 1/4" center hole
6-1/4" Nylock Nuts
Paint for guard and grill
1.The first step is to remove the grill from the jeep. I unbolted my radiator and let it hang by the hoses.
I then unbolted the fenders from the grill, unbolted the rods that connect to the firewall, unhooked
the electrical connections and unbolted the grill from the frame crossmember.
I have a '74 CJ5 that's pretty basic. Later Jeeps may have more to unhook!
2.The next step is to turn the grill upside down and get precise measurments for your expanded metal.
Using your favorite cutting method (I used a die grinder with a cutoff wheel) ensure that your expanded
metal will clear top, bottom and sides. You will also need to cut a opening for your hood saftey catch
if your jeep is so equipped. This would be a good time to paint the expanded metal. I used black
hammerite for rust prevention and the black "hides" the guard so it isn't very noticeable.
Make sure to smooth the edges here with a file!
You don't want to cut yourself reaching for the safety catch!
When the expanded metal is cut to size, and your saftey catch cut out made, set it aside.
Now comes the fun part!
3.Take the carriage bolts and set the heads in the the u-shaped channel that is the backside
of the grill's vertical "teeth". You will want to put three in each of the outside most verticals. You can
space them however you would like, but I put the bottom ones approx 3" from the bottom of the grill
and the tops approx 5". You should now have a grill laying face down with six carriage bolts
sticking up at you.
Now take the exanded metal and put it in place, the carriage bolts going through the holes
of the expanded metal. You will probably have to move the bolts a bit to get the expanded metal
to line up properly. When it does, take a felt tip pen (or other method of marking) and mark where all
the bolts are on the grill. Take the expanded metal off and set aside again. You now have your
points for welding the bolts in.
Make sure the expanded metal lines up with the grill!
4.Now you can weld (or braze--we brazed) the heads of the carriage bolts to the grill.
This is going to ruin the paint on the front of the grill, so be prepared to repaint the grill,
or at least portions of it. Careful not to warp the grill from the heat!
5.When the welds (brazes) have cooled, repaint the grill as needed. Now you are ready for assembly.
Over the carriage bolts slip first a flat washer (this one may need to be a fender washer so that it catches
the edges of the channel properly), then a grommet, then a washer. Now slip the expanded metal over
the bolts and slip a washer over that, then a grommet, then another washer,then the nylock nut.
Tighten everything up being careful not to overtighten. This is your shock mounting, keeping the
expanded metal from vibrating annoyingly!
At this point I cut off the excess bolt length with a die grinder, but you don't have to.
Now you can reinstall the grill--just reverse procedure! *grin*.
Email me with a pic how your's turned out and I'll post it below!
cj5_pilot@yahoo.com
