Author Topic: Grill Build ('12 GMC) (Read 12748 times)

KensAuto · « **on:** May 08, 2016, 08:46:14 PM »

No, not a cooking grill.
This has to be one of the most useless things I have ever done, but it was fun, and helped to get rid of some more chrome.
The nicer ones, with leds, go for 1000-1700 bucks. This one cost me about 100, and 5000 hrs of cheap labor.
First up, taking the GMC emblem off to give me a flat surface....:

...so I could lay out some cardboard:

Then pie cutting some 1.5" flat stock to make the compound bends:

KensAuto · « **Reply #1 on:** May 08, 2016, 08:48:24 PM »

the frame work's pretty much done:

KensAuto · « **Reply #2 on:** May 08, 2016, 08:52:21 PM »

The fun part, drilling 40, 1/4 inch holes dead center:

I had some of this in the shed.....kind of "Denali-ish" if that's a word:

Cut to fit:

KensAuto · « **Reply #3 on:** May 08, 2016, 09:00:07 PM »

This critter showed up from Amazonia...a 28" curved light bar. Had I known how much difficulty this was going to add, because of the curve, I might have went a different route.
So it turns out that the curve of the light matched the original grill perfectly...my version not so much.

I got out this old rusted HF metal brake with rollers and started sanding the rust from the rollers.
I then rolled the screen, and the pieces for the light enclosure/bracket.

Bottom pieces are for the bracket;

KensAuto · « **Reply #4 on:** May 08, 2016, 09:04:09 PM »

Light bracket done, just have to add some ears for mounting the light:

..cutting out the mesh to fit the light:

...all tacked (and where the fun began):

KensAuto · « **Reply #5 on:** May 08, 2016, 09:09:34 PM »

I had to keep rebending it to get it to fit the truck again...that mesh must have been spring steel!! urr ...I bent it so much that my welds started to crack, so they were rewelded, and then redressed.

Trial fit for mounting brackets:

...with brackets welded on:

ready for paint, :

sanded:

KensAuto · « **Reply #6 on:** May 08, 2016, 09:23:24 PM »

Painted satin black (one of my favorite colors)

Chopped up the factory grill (Cringe):

...leaving one inch sections on the sides for the insert to rest against. they were sanded and painted black.
The middle stubs will have 1/4" screws for mounting as well as the top and bottom brackets:

Bigdave_185 · « **Reply #7 on:** May 08, 2016, 09:34:52 PM »

Looks like a whole lot of goodness

Raising boys into RealMen!!

stlaser · « **Reply #8 on:** May 08, 2016, 09:37:07 PM »

Looking good Ken!!!!!

Sammconn · « **Reply #9 on:** May 08, 2016, 11:03:39 PM »

Ah man. I so like what you are doing...

KensAuto · « **Reply #10 on:** May 08, 2016, 11:27:02 PM »

Thanks Guys! My goal was to make it completely different from the name brands that are out there. they currently offer them with the light at the top, or the bottom...not in the center (or none that I know of for GMs)

Final pics. After the test drive tonight, I had to tilt it down quite a bit, so the light isn't all even like in the pics.

Sammconn · « **Reply #11 on:** May 08, 2016, 11:31:20 PM »

Looks awesome Ken! As long as it doesn't get contagious.

I'd have to find some of that mesh, or similar, looks legit!

KensAuto · « **Reply #12 on:** May 08, 2016, 11:37:26 PM »

It may overheat now, but at least it'll look good on the side of the road.

BobbyB · « **Reply #13 on:** May 09, 2016, 02:25:37 AM »

Looks good Ken.

cudakidd53 · « **Reply #14 on:** May 09, 2016, 07:01:38 AM »

Very nice work there Ken ;)

fenriswolf039 · « **Reply #15 on:** May 09, 2016, 07:31:40 AM »

That thing looks beefy!

Flyin6 · « **Reply #16 on:** May 09, 2016, 09:22:19 AM »

You are one creative dude!!!

And that's coming from another creative dude!

EL TATE · « **Reply #17 on:** May 09, 2016, 09:53:29 AM »

When do you start production on the RMTS grills commercially again?

Flyin6 · « **Reply #18 on:** May 09, 2016, 10:02:56 AM »

Quote from: EL TATE on May 09, 2016, 09:53:29 AM

When do you start production on the RMTS grills commercially again?

I love it!

In more ways than one!

KensAuto · « **Reply #19 on:** May 09, 2016, 10:21:41 AM »

Thanks fellow creative men!

Flyin6 · « **Reply #20 on:** May 09, 2016, 10:23:46 AM »

Quote from: KensAuto on May 09, 2016, 10:21:41 AM

Thanks fellow creative men!

I stand corrected!

cj7ox · « **Reply #21 on:** May 11, 2016, 11:58:06 AM »

Great looking grill!

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moto123 · « **Reply #22 on:** May 11, 2016, 01:08:57 PM »

Quote from: KensAuto on May 08, 2016, 11:37:26 PM

It may overheat now, but at least it'll look good on the side of the road.

That was my first thought, your free area was reduced by at least half. Let us know how it runs on a hot day. But it sure does look awesome!

KensAuto · « **Reply #23 on:** May 11, 2016, 01:28:18 PM »

As long as I don't block off that bumper opening I should be good. Also need to remember that when the new bumper gets built...might have to leave a few slits down there.

KensAuto · « **Reply #24 on:** May 17, 2016, 01:40:20 PM »

Quote from: moto123 on May 11, 2016, 01:08:57 PM

That was my first thought, your free area was reduced by at least half. Let us know how it runs on a hot day. But it sure does look awesome!

Small update. I ran around Pheonix this weekend. Not terribly hot, but in stop/go traffic it was warm none the less. The truck came up to 195* and stayed there til I got home. The only problem was that it threw the outside temp gauge off by 9*....it was showing 101 when actual was 92. That tells me there's some dead air in front of the condensor.....so now I might be running higher a/c pressures than before. I relocated the sensor down by the bumper slot and temps are back to being accurate.

The true test will come this weekend when I haul 17k up the mountains to take the wife camping.....and taking enough tools to rip that grill out if needed!

stlaser · « **Reply #25 on:** May 17, 2016, 03:30:56 PM »

Ken, is there room to recess that light back in a little deeper to give air flow in around the light versus having the light flush & no air flow where the light resides currently?

KensAuto · « **Reply #26 on:** May 17, 2016, 04:31:52 PM »

Good question. I had to cut the latch/old grill/crash sensor bracket to get the light were it is...I would have to completely remove the bracket to push the light back anymore. I think when I get time, I'll drill everyone of those 3,429 holes out about 2 sizes.

I really like the look, but there's a reason most companys use wire mesh in front of a radiator. :(

TexasRedNeck · « **Reply #27 on:** May 17, 2016, 09:30:09 PM »

Ken I'll take one for my LML please. Invoice me when you are done.

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KensAuto · « **Reply #28 on:** May 20, 2016, 08:02:33 AM »

Hmm. ..was that a compliment?

Thank you sir. .. Goin up the hill here shortly. ..hope she stays cool.

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KensAuto · « **Reply #29 on:** May 20, 2016, 10:20:31 AM »

Dangit

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stlaser · « **Reply #30 on:** May 20, 2016, 11:46:16 AM »

So I take it the grill is the problem & you're not over loaded hauling Hillary around in that trailer?

Sorry, don't take enjoyment in your pain but it was too good to pass up Ken.....

EL TATE · « **Reply #31 on:** May 20, 2016, 12:44:11 PM »

Awe Ken, now you're vacationing like me!

Dawg25385 · « **Reply #32 on:** May 21, 2016, 11:01:22 PM »

Looks real nice there Ken

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TexasRedNeck · « **Reply #33 on:** May 21, 2016, 11:11:31 PM »

Yes, Ken, I compliment. I like it a lot.

What happened that put you on the side of the road?

moto123 · « **Reply #34 on:** May 22, 2016, 07:59:54 AM »

That's not fun. How high did the temp get before you had to stop? I assume removing it fix the problem, because we haven't seen any other posts so you must still be driving.

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stlaser · « **Reply #35 on:** May 22, 2016, 09:40:15 AM »

I think he called a semi wrecker in to haul Hillary away.....

KensAuto · « **Reply #36 on:** May 23, 2016, 04:25:09 PM »

Hey guys, just made it home. No service where I was, which was kinda nice.

Truck was hitting 225* on the smaller hills, and only 65* ambient. There's no way it would take on the couple of long 6-7% grades between me and my destination, so I pulled it off. The entire rest of the way I was thinking "I hope I don't hit a bird without a grill".

....I guess our lord has a slight sense of humor because I avoided several birds....just before smacking a deer! I slammed on the brakes so hard that everything in the trailer got rearranged, including the ranger after it ripped free from it's tiedowns. The deer missed the grill area (by ---this---much), but caught the bumper.
That all happened 1 mile from a temporary ADOT sign that was lit up with "Watch For Elk". ugh

Then, after setting up camp, we were informed by the forest service that we were about 2 miles from the current largest wildfire in AZ, and that we might want to move since we were directly in it's path, with winds gusting 35.
http://inciweb.nwcg.gov/incident/4743/

So, we stayed, hoping for some excitement, and maybe an insurance claim for a new truck and trailer. Sorry to say, we were neither excited, nor driving a new truck at the end of the trip.

Climbed a hill to get a better view:

No blood, just hair:

Sammconn · « **Reply #37 on:** May 23, 2016, 08:42:54 PM »

Well that's a bit more excitement than you bargained for.
It's really too bad that the grill is blocking that much air flow.

TexasRedNeck · « **Reply #38 on:** May 23, 2016, 09:54:04 PM »

Glad you're OK Ken. So the temps dropped back down on the hills once you pulled it?

KensAuto · « **Reply #39 on:** May 23, 2016, 09:58:55 PM »

Yeah, all was fine immediately after.

Still want one? I have one ready to ship, just for you. lol

I'll fix it....I have to.....it's not like I can put the old one back in.
My dear wife suggested building a different one...one for towing the trailer, and this one for, well, looks. ...and she's not even blonde.

Sammconn · « **Reply #40 on:** May 23, 2016, 10:10:25 PM »

Well, it sounds like she has a plan for you. Lol.

Dawg25385 · « **Reply #41 on:** May 23, 2016, 11:42:46 PM »

Gonna drill out the holes to make them bigger??

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cudakidd53 · « **Reply #42 on:** May 24, 2016, 07:13:46 AM »

Glad you're ok Ken- did you at least get back straps outta the deal? Nothin like fresh Bambi-Q over a camp/forest fire!

KensAuto · « **Reply #43 on:** May 24, 2016, 10:18:50 AM »

Never looked back Mike. Wifey was freaking out so I told her I saw it jump up and run away. :(

EL TATE · « **Reply #44 on:** May 24, 2016, 10:58:29 AM »

I told that fib before too. then when we got to the campground I quietly pulled the quail out of the fender well. Glad you didn't get the "cab roll through the windshield" version

KensAuto · « **Reply #45 on:** May 24, 2016, 11:05:08 AM »

Yeah, that would've sucked. Also glad it wasn't an elk...they are out and about in full force right now.

Kyle, I'm probably going to cut it apart and use regular mesh, like the Name Brands use.

KensAuto · « **Reply #46 on:** May 30, 2016, 06:34:19 PM »

Round 2.

Couldn't bring myself to start over from scratch, even though it would've been a lot easier.
First, covered the mesh with tape and started laying out a pattern. Diamonds seemed to work the best:

KensAuto · « **Reply #47 on:** May 30, 2016, 06:35:34 PM »

Then flipped it over and used a gray sharpie to copy the pattern (the tape was somewhat see through):

KensAuto · « **Reply #48 on:** May 30, 2016, 06:41:07 PM »

A couple days worth of destroying cut-off wheels, and about a dozen mini roloc grinding discs later, here's the latest version. If this doesn't work, I'm going back to sleeping in a tent....it weighs less than the trailer by a few pounds, I think !!!!

Sammconn · « **Reply #49 on:** May 30, 2016, 09:35:17 PM »

Well that looks pretty good Ken!
Hope it works out, you've got a lot of sweat and time in this now.