Mesh Grill write up

[Disco Muppet]

Hi folks.
Just a quick write up of how I did my mesh grill on the D2, some costs involved, pointers etc. I realise there are other threads on this, however I found them to be a bit light on some info.

So, first step, open the bonnet, and remove the grill. To do this you have to undo the three screws in the top, and remove the clips they sit in. You'll also need to remove the hockey sticks from underneath the headlights, by undoing the screws in the forward face of the wheel arch. Then you can access the lower screws on each side of the grill.

Next, what I did was clip the ribs between the plastic panels, to make removal easier.

https://www.aulro.com/afvb/images/imported/2014/03/402.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-23153646_zps1192daf5.jpg.html)

Next I cut the middle section out with a dremel tool. I didn't have one prior to this, however I found a good 200 piece kit at Jaycar for $39. Cheapo I know, but it works fine.

So after cutting out the middle section, I began to tidy up the dags left behind, as well as starting to remove some more of the surrounding plastic.
Next step was removing the slanted face from the lower panel

https://www.aulro.com/afvb/images/imported/2014/03/403.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-23154322_zps9bde8928.jpg.html)

I taped the edge up and marked it.

https://www.aulro.com/afvb/images/imported/2014/03/404.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-23170035_zps27976f03.jpg.html)

I also cut it into sections to make getting a straight edge a bit easier.

So then I was left with this...

https://www.aulro.com/afvb/images/imported/2014/03/405.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-23174931_zps399d1c1a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/03/406.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-23180408_zps10de2f58.jpg.html)

Considered leaving the bottom black panel in but decided it would look better without, so out it came.

https://www.aulro.com/afvb/images/imported/2014/03/407.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24125124_zps8898781c.jpg.html)

Next, I wanted to cap the edges so it looked a bit tidier, at least along the paint edged sides as if I got too close to really tidy them up then I'd risk marking the paint, so I slit some fly screen tubing, or spline as it's called, and used that. I'd recommend getting some proper edging, as trying to sikaflex spline onto an edge was a bloody nightmare!


https://www.aulro.com/afvb/images/imported/2014/03/408.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24135615_zps050a8125.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/03/409.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24141820_zps3f10d72d.jpg.html)

Next I laid the mesh on top to get an idea of where I needed to cut it, which took some back and forth work to get it correct. It's just generic auto mesh from SCA, for about $30

https://www.aulro.com/afvb/images/imported/2014/03/410.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24151237_zpsef081c01.jpg.html)

This is with the mesh sitting in before sikaflexing

https://www.aulro.com/afvb/images/imported/2014/03/411.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24155839_zpsda492976.jpg.html)

Next, I sand papered and wire brushed the plastic, as well as giving it a thorough clean with some turps to ensure a good bond and sikaflexed it up.
I then place the mesh in, although I had put it in before to allow me to bend the edges over so they sat flat against the plastic. And by bend I mean bash with the brush handle :angel:

https://www.aulro.com/afvb/images/imported/2014/03/412.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24175201_zps32c9f16b.jpg.html)

Let it set, put it back together and hey presto :)

https://www.aulro.com/afvb/images/imported/2014/03/413.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24201812_zpsfb0d144c.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/03/414.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-24203223_zpse3a0a7c5.jpg.html)

It needs more work, there are quite a few sikaflexy fingerprints that need cleaning, and part of the top section wasn't pressed into the sikaflex enough but it's still remarkably sturdy.

A quick rundown of costs:

Mesh: $30
Dremel tool: $40
Sikaflex and caulk gun: $32
Allow $10 or so for any other odds and ends you might need if you don't already have them.

All in all, a pretty easy and cheap mod that looks much better, and hopefully better airflow.
Cheers
Muppet :)

[gavinwibrow]

Noice. Now if you just add a flyscreen removeable mesh, you will stop the bugs at night, during plagues etc

[Yorkie]

Chrome mirrors and door handles next?. :D

[Disco Muppet]

Chrome mirrors and door handles next?. :D

22" chrome spinners.
Bling Bling yo :p
Gav, any bugs are going to be cut to shreds, sharp stuff :D

[Disco Muppet]

And with the badge on :)

https://www.aulro.com/afvb/images/imported/2014/03/340.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/Messenger_5854177961153349025_13957447915451742_zp s3ec2009c.jpg.html)

Might upgrade to a black one later on :cool:

[singlecell]

Looks good, I am a fan of a mesh grill. Some daytimes photos would be great.

[Disco Muppet]

Sure thing.

https://www.aulro.com/afvb/images/imported/2014/05/838.jpg (http://s1166.photobucket.com/user/DiscoMuppet/media/2014-03-26150941_zpsf3cba29a.jpg.html)

[dullbird]

Mesh looks good, badge looks pants :)

I'd take the badge off looks like an afterthought. The badges on the grills are usually offset so seeing it in the centre makes it look weird

[Slunnie]

The grill looked good Muppet, I was impressed. Well done with it.

[joel0407]

Looks good. Some thing I'd do if I had cooling issues.

I might still, just for the cooling benifit.

Happy Days

[Disco Muppet]

Mesh looks good, badge looks pants :)

I'd take the badge off looks like an afterthought. The badges on the grills are usually offset so seeing it in the centre makes it look weird

Enter the argument that had plagued me for several days and drew schisms between friends, family, and SWMBO :lol2:
Genuine Saudi Grill has them centred ;)
I'll do some thinking about it :cool:

Slunnie and Joel, Cheers!
TBH it was more just aesthetics rather than much practical purpose, although if it helps then I won't object.
The original grill was cracked and broken in the plastic so that also motivated me :D

[bell1975]

Good on you for taking the time to do the pictorial Muppet. It's made me think twice about doing it to mine. I really like the Saudi grille and yours looks pretty close to it but it's a fair bit of faffing about with the Dremel.

I found this in case someone wants the easy option (won't look as tidy as the Saudi option I'm sure (or yours Muppet)). I'm going to order one soon and will post back with how it looks.

4WD Radiator Grille Insect Mesh Screen Land Rover Discovery 2 99 (http://www.ebay.com.au/itm/200766216899'ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1438.l2649)

[Disco Muppet]

It's definitely a job with limited scope for error.
TBH it took me a long time, lots of stopping and starting, gathering up bits, etc.
If you're confident with a dremel, you could do all the required cutting in about 30 minutes. Would definitely help to rule some lines and have a decent cutting disk, some folks even use angle grinders.

The mesh inserts are great for keeping out grass seeds, insects, etc but I'd wager they reduce cooling if anything, which kind of put me off them.
all in all my grill was pretty ratty, so if I stuffed it then it wasn't a huge loss. But I'm pleased with it, it's holding together fine.

Cheers
Muppet :)