This is a great alternative mod on a budget if you don't feel like paying $1,200 for an RBP grill.
- 4 sheets of 6"x36" gutter guard ($1.94/sheet at Home Depot)
- bag of zip ties
- wire cutters
- dremel with metal cutting disk
- safety glasses
- ratchet with an 8mm socket and 10mm
opening the hood of the truck. Look at the backside of the grill shell and on my 2003, there was a thin metal tube bolted to the underside of the hood and it ran down the side of the shell, across the bottom, up the other side, and back to the underside of the hood.
There are six 8mm bolts holding the tube to the bottom of the grill shell, go ahead and remove them. On the top left and top right corners of the shell, there should be a 10mm screw holding the shell to the hood, go ahead and remove those. Across the top, there will be 8mm nuts holding the shell to the hood so also remove those. Once you have all the nuts and bolts removed, the grill should slide right off. See the image below .
Now lay your grill face down on something soft so you don't scratch it. I used a towel. On the back side, you will see that the honeycomb inserts are attached by push pins. The only bad thing about mine was the pins didn't have a shoulder to use to pull the pin out and compress the extensions to allow an easy way to remove them, so I went all out on them with the screwdriver, knife, and pliers. See below images.
Now, take one of the strips of gutter guard and hold it over one of the grill holes. Measure where you want to cut, and make sure to give yourself plenty of room width-wise as the sheets are barely tall enough to fill the hole. I cut my sheets with a small dremel tool and a metal cutting disk, it's up to you if you want to use tin snips, or something else.
After cutting the 4 pieces, I put the zip ties through the guard, close to the edge so it wasn't very visible from the outside, and through the holes where the push pins were. You can do this any way, I won't post mine because it's quite horrible
When you have all the zip ties in place, then you can tighten them one by one making sure to go to different sides so you don't pull the guard too much to one side. On my 2003 grill, the holes the push pins went through are taller or shorter than the shoulder of the hole in the grill so I had to work the mesh to fit correctly, but there are still some bad spots on mine so don't worry.
Once you have all 4 pieces secured, you can put the grill back on the same way you took it off. Congratulations on completing your very own gutter grill! There are some spots that aren't flush with the grill because of the zip ties, but it's fine to me. Now I just need to figure out if I should paint mine black
For the most part, the new grill inserts look great besides the bad spots where it's rolling inwards towards the radiator, but it's not noticeable from at least a few feet away. This was a very easy mod to do, and very cheap! All I had to buy was the four sheets of gutter guard and a bag of zip ties.
Hi-def pics: http://img32.imageshack.us/img32/4631/dscn1068k.jpg
I also did this on my 2006 and the mesh fits a little better with the redesigned 06+ shells.