During Christmas break the weather was pretty warm, 80* on Christmas Day. As I was traveling in the Disco I was noticing the engine temps were higher than normal when cruising at 70-75mph. It was hitting 208, which isn't bad but with a 180* thermostat it shouldn't be that high. I pulled over and removed the three lights from the bumper thinking they may be blocking some of the air flow. I really didn't think it would make much difference, but once back on the road the temps never went over 194*.
I really don't want to remove the lights permanently, so I am trying a few things now to get more air through the grill. With the winch and stock grill there really wasn't a lot of open area in the grill. I decided first I would try to make my own "Saudi grill" using an 03-04 grill.
First I found another grill at a local pull-a-part I could modify. Then I cut out the center section of the grill.
Next I used some ABS I had laying around and epoxied it from the backside of the grill to the area that was left open from cutting the center section out.
I ordered a piece of black vinyl coated square mesh for the grill.
After cutting and shaping it to fit, this is what it looks like.
The mesh will be held in with a few screws, washers and nylock nuts.
Next up, I'll be filling the voids left from cutting the center section out with fiberglass, sand smooth and then paint black. I'll have to cut the lower portion of the grill to fit over the winch also. This should allow more air through nicely.
I have another idea that will help also, I'll detail that soon.