I finally got around to changing the grill inserts on my truck. I bought a sheet of galvanized mesh from the hardware store for around $8 and a can of flat black spray paint. Here's a brief list of the project.
1. Cut out two pieces measuring 21.5" x 14.5" using a cutoff wheel on a dremel tool. (Side cutters or tin snips would probably work too.)
2. Spray several coats of paint on both sides of the mesh.
3. Lay out the painted mesh on the back of the grill. Ensure roughly .25" overlays around the edges. I used a set of side cutters to trim any excess. I also made relief cuts on the sides where the push-lock fittings where holding the old grill insert.
4. Run zip ties through the holes of the mesh to secure in place.
5. Once I made sure all the zip ties were tightened down, I used a flat blade screw driver to mold the excess mess around the edges of the grill.
6. Finally, I took a tennis ball and rolled the mesh to help fill out the edges and give it a smoother appearance.
I've only had it on a few days but so far it seems to be holding up pretty well. Once all the rain stops I'll take a few better close up pics. In the meantime, here's a few quick pictures I took in case anyone else is interested. Enjoy!
Half and half - Which look is better?
Finished product before I put it back on the truck.
Close up.