I like most customized grills so long as they are not gawdy or garish. I almost settled on the billet type, but they became more and more popular, and I am different, one of a kind. Walking thru an ACE Hardware store a precut piece of small diamond pattern material just grabbed at me and said"Take me, Take me, I'm yours". Now how can you refuse a deal like that. It was about 3/16th inch thick, sturdy but not weghty, so I bought 2 pieces 16 x 30 1/2. Wasn't for sure exactly on my design, but knew I didn't want a wide chrome flat band around the perimeter and the mesh chromed too. I laid it out at home and chalked it with the stock grille overlayed. seemed to work so went to a welding shop that did nice ornamental iron and negotiated the deal. The biggest problem was the stock grille was not flat. It had compound curves. He cut the shape and welded 1/2 flat strap all around the perimeter, but left an opening to reach in and prees the lever to open the hood. I'm not happy with this, but after all it was a prototype, so next one, if there is a next one, will be a little different.
Most of one sheet was used for the upper grille and one side of the lower grille. Fitting the upper with the flat strap was a bear but finally got it worked out.The lower grilles for the air dam worked perfect. I found some 3/8" steel rod in his shop and told him to make the frame with that and then tack the mesh to it. Next upper grille will have this rod for the frame also.
I then took the pieces to a nearby paint and bake shop and for $55 he sandblasted the three pieces, wire brushed them and ground them smooth. Then he powder coated the items with matching Alabastar and baked them.
I'm satisfied with the finished products except for the upper grille opening and flat strap The cost was of course, as with any first one-off more than I had planned, apout $350 labor and materials, including powder coat and exra time on the upper grille getting it to match the curve and sit in the opening. Saddest part is the owner of the shop had lung cancer and passed away about 2 months after the project was done. His widow couldn't run the business so she sold out lot, building, and materials, putting the two brothers that did the ornamental stuff out of work. it's still a one of a kind as far as I know.
I have dubbed the Crossie "SNOW WHITE", The car was just repainted in June with HOK PEARL
code "SNOW WHITE", and the grille took it nicely.

first pic has been pearled, next SNOW WHITE, Before Pearl, prototype with "hangers", Pearled Engine Cover waiting to be air brushed

John P
FTroopChief