Nice effort. I think you have found it isn't as easy as it looks to make a grille for our babies.

How durable is the mesh fabric you used. It looks a little fine and would probably bend easily ( from the picture anyway). I noticed it is very far back at the top. Did you cut it around the hood release? When I was first working on my prototype, once I closed the hood I couldn't reach the latch to release it. I had to cut the grille away to get it open.

The picture of the grille you liked is actually mounted behind the bumper edge. look closely and you will see a small lip from the edge of the bumper at the bottom of the grille. I tried this as well and felt it looked very unfinished.

The heavy surround on my grilles actually serves the purpose of maintaining the rigidity of the grill along with the heavy stainless mesh fabric.

The best solution would be to have a molded plastic grille that matches all the contours of the opening. The curve around the bottom edge in the middle seems to be hard to match. Look closely at the new Bently mesh grille and you will see it isn't metal at all but molded plastic with a chrome finish. Unfortunately the process takes about $10K - $15K up front and I could not convince any of the companies to move forward on it. We needed a firm commitment of 200 people to get the price down to $300 and I could never muster more than 10.

Good luck and I hope you succeed. You can't have too many options!