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  #1  
Old September 15th, 2010, 02:23 PM
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Andrew J. Hutton
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Defender Grille.

I'm in the process of building a new grille, after going back and forth on ideas we decided to go with a stainless frame and woven wire mesh, similar to that used on the Series II, the next thing is to decide what size of mesh to use and I'd love to hear opinions on this, I think anything from 1" down to about 1/2" would look pretty good. I hope to have the first one finished next week for photos and will make more if the costs are reasonable, and I'm hoping they will be.
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  #2  
Old September 15th, 2010, 02:47 PM
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Jason England
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include a fine mesh to keep the flies out!
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  #3  
Old September 15th, 2010, 03:13 PM
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Andrew J. Hutton
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What I was actually thinking was to put some extra holes or hooks on the front so that a seed-guard could be put in front when needed, a seed guard is a finer mesh that keeps grass-seed from plugging up your intercooler/radiator when driving across a field, usually they're just strapped on like a mesh rad-muff. Having the welded wire backing it means the seed guard can be a flexible mesh that can be rolled up and stored. Perhaps some tapped holes in the front normally blocked with screws that you could put snap heads into for attaching the guard or a rad-muff in the winter would work.
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  #4  
Old September 15th, 2010, 03:35 PM
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have you seen the wolf military grills ? STC60096
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  #5  
Old September 15th, 2010, 03:44 PM
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Andrew J. Hutton
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Yes, similar idea but since I'm using stainless woven wire I don't think the additional stiffeners will be required, also the frame will be 3/8" thick and beveled on the edges which will make it not look so "flat" like the stamped out options out there. I also like the tie-in with the original grilles since they were also woven wire. The overall surface area for air-flow should be 10-15% higher than the Wolf one while still providing durable protection for rock impacts (which with the custom intercooler I had made is one of my big concerns)

Hopefully I'll have photos by next week.
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  #6  
Old September 15th, 2010, 07:38 PM
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i might be interested in something like this down the line if you offer them for sale.
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  #7  
Old September 28th, 2010, 01:37 PM
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Andrew J. Hutton
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Quote:
Originally Posted by hillstrubl View Post
i might be interested in something like this down the line if you offer them for sale.
Here's a sketch of roughly what the basic one would look like. We could also do extended ones for models with AC and ones with winch cut-outs for those of us with close fitting winches and light mounting rings for fitting things like the 90mm Hella fog and DRL modules.

Not pictured is an oval welded in a location of your choice for the Land Rover logo (or left off if you so choose).

I found a supplier for 304 Stainless in the 0.75" opening crimped woven wire with 0.12" thick wire that closely matches that used in the Series I and II grilles and the borders will be 3/8" thick stainless with a bevel on the inner and outer edges and the mesh will be tig-welded into a machined recess in the rear of the grille for some serious strength since my objective personally was to go a grille that both looked good and could keep a large rock from going through my intercooler. The thicker border material was picked to allow it to blend in more with the lamp finishers and give it some beef vs the punched out and pressed metal grilles out there now, the .75" mesh should also flow more air than the other designs and help both intercooler and rad performance.

I would love to get feedback at this point, is this something you think would look good, would you like it available powder coated? etc, what do you think a realistic target cost would be? Would having snaps on the front to make attaching a rad muff or seed screen be something you'd like to see?

If there was interest we could also do matching wing-top and wing-side vent covers and possibly lamp-guards as well (though I'm leaning towards using Acrylic myself for the lamp guards since that's easier to clean the bugs and mud off).

I'm going to be ordering the materials later this week, if you're interested drop me a note and I can keep you up to date on projected costs.
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  #8  
Old September 28th, 2010, 01:40 PM
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i like it, any idea a ballpark cost? What were you thinking for color? As long as its not super shiny/chromed in some way I may be interested. I haven't had my 90 in the winter yet so I'm not sure if i'd need a radiator muff (and snaps for it).
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  #9  
Old September 28th, 2010, 01:49 PM
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Andrew J. Hutton
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I want to be cheaper than the Heritage grille, but I'm waiting on some materials costs right now and will just need to figure out the labour on top of that. The goal is something really cool and right now it would be just plain stainless but could be powder coated or painted any colour you wanted.

My idea for the snaps is to have them where the machine screws are, so you could put them on just by removing the screws and inserting the snap bases behind them. I'll need to test to see if additional securing points would be needed or not.
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  #10  
Old September 28th, 2010, 02:13 PM
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The outside is round bar stock. I would use normal steel and galvanize it. Basically reproduce a stage one V8 grill but with Defender style mounts.
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  #11  
Old September 28th, 2010, 08:11 PM
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Andrew J. Hutton
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I am not familiar with the RN one but not like the Stage One other than the mesh. The frame will be 1.5" stainless 3/8" thick and machined to give it some substance unlike the punched out ones commonly available in the uk which in my opinion just don't look substantial.
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  #12  
Old September 28th, 2010, 08:37 PM
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Be careful of running with a seed guard on the road,it cuts airflow by at least half.
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  #13  
Old September 28th, 2010, 09:11 PM
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Als watch the weight... The Grill panel was only made to hold a plastic grill... Now what would be nice is to replace the whole panel with a integrated mesh panel....
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  #14  
Old October 7th, 2010, 03:20 PM
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Andrew J. Hutton
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I've managed to source both 304 stainless and mild-steel in 3/4" crimp weave, needless to say the stainless is significantly more expensive but personally I feel it would be worth it. I am wondering what the demand would be for each type, this would let me get the costs as low as possible. A mild-steel version would of course need to be either electroplated or hot-dipped (I would lean towards the first for cosmetic reasons but the custom is king right? ).

If a stainless one could be done for say $250 each, do you think there would be enough demand to produce 60 of them? (We could also do matching wing and wing-top vent covers but not sure on a cost for those yet), would getting it down to $200 increase your interest? I'm also looking at machining out the front face to resemble the heritage model as well, either for all of them or as an option.

If there is enough demand to justify this I'll start getting things ordered, I just don't want to get stuck with 5 sheets of wire mesh
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  #15  
Old October 7th, 2010, 05:01 PM
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Julien Dalbin
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we need pics, make one and post some porn !
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  #16  
Old October 7th, 2010, 08:20 PM
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If the attention to detail is the same as your other offerings I'm sure it will be a quality upgrade... But I agree some pictures will help you sell them..... If you need a beta tester count me in... Now i need to sell of some more spares lying around my garage...

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  #17  
Old October 19th, 2010, 09:40 PM
ajh
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Andrew J. Hutton
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I have managed to get a sample of a woven mesh that is quite close to the series one (which is actually closer to 1" than 3/4") it is round vs flat but I think it looks even better.

Hope to have a prototype in a few weeks and will likely also do.some series ones at the same time.
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  #18  
Old July 11th, 2012, 10:47 PM
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Old thread. Did you ever make this?
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  #19  
Old August 18th, 2012, 07:26 PM
ajh
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Andrew J. Hutton
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The machinist I was working with retired but I resurrected the project when I saw your post and the new shop is much larger and specializes in high-precision and is fairly busy at the moment but we're exploring options and will produce some prototypes as soon as they have some free-time.
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  #20  
Old August 19th, 2012, 09:05 AM
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Great! Well please let us know about any new items.
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