How to Make Custom Grill
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better picture soon

Its a good Idea to get an extra grill before attempting this.  I got mine from a junk yard online.  The first time I tried this I broke the grill because I was in a rush.  So take your time!

factory grill

The first step is to remove the mounting bolts and cut the grill to get rid of the slats and get the desired shape.  Be very careful when cutting this is my second attempt the first one broke when cutting and hit the bolts.  Make sure you leave the top two and bottom two bolt locations on the grill or else you will not have any way to mount it.  I filed the bottom ones flat and brought the depth of the bottom to 1/8" less than the bolt holders so the mesh could sit in front of the bolts.   The top bolts I just made smooth because They are not visible.  I didn't like the way the grill dipped down for the emblem so I shaved it straight. It should now look like the picture below.
cut and shaped

Next you need to smooth the grill and shape the top.  I used a small belt sander and a file to smooth the bottom and sides.  Then fill any imperfection and the emblem hole and cut with bondo and sand till smooth.
shaping and smoothing

Next step is to cut the mesh to fit the inside of the grill make sure to leave it a little larger so you wont see any gaps.  I was able to bend it around inside the grill to keep it in place.  cut the bottom around the bolts but leave it tight so you have to force it around the tabs.

fitting mesh

After every thing is shaped and fit I primed and painted the grill.   I put many coats on so any chips wouldn't show. Then I put the emblem from the trunk in the center of the grill.
ready for fitting

After the grill is finished you remove the factory grill and paint the grill cavity with a flat black or else you will see the hood support like in the picture below

hood support needs painting

Finished
finished