I thought there was a write up. Didn’t find one so thought I’d post the tear down.

note - I plan on putting the Land Rover Badge meshed in with the grill.. ran out of time #kids.

tools used:
Threaded Rivot Fastner
Dremel - this made cutting a breeze
heavy duty Wire Cutters
Drill & Drill bits - for the rivot holes to tap.

parts:

• Grill mesh(went with the largest for flow)

Amazon

• Threaded Rivots & Hardware (harbor frieght). Stainless steel and aluminum for rust prevention.
  • I decided on riveting the mesh grill to make it serviceable.

Quick n dirty (I didn’t clean it.. why bother it’s tan).

oh “What are thooose”! Answer at the bottom.. 😜



Mesh and back end of front grill… on the bench ready to choppy chop.

Using the Dremel. And a diamond flat head it took me 30 minutes to cut through the plastic. Remember take off less you can always trim more later. Can’t put it back. 😳

Test fitting and measuring the mesh

Ok.. I cut the mesh to short 🤦🏻‍♂️😱. So now I made it a wrap. Hardware screw for Rivot in shot for comparison.

Harbor Frieght hardware kit… I made sure the rivot tool set matched the thread and size.

Final assembly with 5 rivot points.

Final assembly - Angles shot to show the “side” that you need to make sure you have enough coverage…

Final Assembly - front. With angle so you can see where the rivots are.

Final Assembly - Ledt angle. Notice the top center rivot. (It doesn’t have hardware yet) but the rivot on the inside pokes out enough. The mesh wire wraps around it to keep it secure for now..

Test Fit - Installed front

Test Fit - you can see 2 of the lower rivots.. meh. Least if a bird nukes it.. I can swap it.

Test Fit - Close up. I’m glad I did the rivot method. It’s just 10 more minutes of work and makes it replaceable.


“What are thooose!!” - Head Lights are from tuff-Rok.com UK based. I wrote a review. These are bar none the best “aftermarket” headlight upgrades I’ve seen. To the point I’ve been lazy of replacing my off road lights… 😂


that’s it.. it’s now ready for “Climate Change” 110* weather 🥵

 

I did something very similar.

Sourced a second stock grill
Cut it out to be used as a frame
Used rain gutter mesh
Expoxy
Spray paint
Peeled the badge off and glued it

Related. I used mesh to make guards that attach to the bumper protecting the lights and grill. We take the D2 in to some mountain passes in BC Canada that I swear use marble sized grit during the winter. Blocks the head lights output a bit but not too much.

 

That a flag in the grill mesh!? Hehehe that’s awesome man. Very subtle @Sean Maginness and thanks for sharing.

main reason I did this is the replacement flood lights are 40% larger then what’s on there.

 

interesting in that the 03/04 grille is not “framed” on the edges like the earlier grilles. I can’t quite see how you handled that and finished off the sides. Can you post more detailed photos and/or explain how you dealt with the unfinished sides?
thanks

 

I Ieft the sides "open". Barely can see them with bumper and light bar 🤷🏻‍♂️

 

I’ve seen your truck around a few times while I’m out and about, nice build! I’ll have to see if I can take a closer look at the grill next time!

 

Dude that's amazing!