How to Make Your Own Truck Grill


Making your own truck grill begins with a design concept. From there, you have the choice of a wide range of materials to suit your design. You may prefer the look of horizontal rails or diamond mesh in chrome, natural or a painted finish. Many older trucks have recessed headlights or turn signals that can be trimmed with the original rings. Newer truck grills are one-piece inserts that can be replaced with any type of self-venting material. Decide on a design and obtain the material to make your own truck grill.

Things You'll Need

  • Cardboard
  • Utility knife
  • Grill material
  • Felt tip marker
  • Electric jigsaw (variable speed)
  • Finish jigsaw blade
  • Flat file
  • Electric drill
  • Drill bits
  • Make a template for the grill using cardboard and a utility knife. You can make the template to fit the grill opening or lay the existing grill on the cardboard and trace the outline with the knife. A template ensures you fabricate the grill to the correct dimensions and have correct locations for any lights.

  • Place the grill material on a worktable or workbench. If you are making a grill with sections of tubing or chrome strips, space the pieces according to your design.

  • Position the template atop the material. Transfer the outline of the template onto the material using a felt tip marker. Use a yellow or white marker for outlining darker material.

  • Cut the mesh or individual pieces with a variable-speed electric jigsaw and a finish blade. Use the slowest speed possible to prevent the edges of mesh from chattering as you make the cuts.

  • Smooth the cuts with a flat file. File downward from the finished side of the material using light strokes. Avoid filing upward along the edges or you may ruin the finish.

  • Position the grill in place on the truck. Mark any areas or sections that need to be detailed to ensure a tidy fit. Mark the locations of attachment bolts or clips.

  • Detail the grill as needed using the flat file. Drill the holes for the attachment bolts or clips using an electric drill and the appropriate size drill bit.

Tips & Warnings

  • Solder vertical bars on the back of a spaced grill and drill the bars for attachment bolts or clips.
  • Attach the manufacturer's logo or designer logo using stainless steel bolts with nylon washers and lock nuts.
  • Look at truck project websites or magazine for design ideas.

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  • Photo Credit Jupiterimages/ Images
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