What about using CJ buckets and chrome rings? that would really add something to the appeal for some. Tim
Updating (backdating?) the TJ grille
- Thread starter jscherb
- Start date
OP
You mean ones like these on the CJ grille on my LJ?
That's possible, but it would require a new mold master and a new mold. The reason is that the face of the TJ grille is curved forward and the face of the CJ grille is flat with a slight recess. What I'd do is cut out the forward curve where the headlights mount and replace it with a flat section so the CJ parts could mount. It is possible to do it.
I have thought about doing a more backdated TJ grille; a while back I did this design study to see how an MB grille design would have to change in order to look right on the TJ.
The outline is the TJ grille size and shape and left to right - the factory MB grille, then the factory MB grille reduced in height to fit the TJ grille height and finally adjustment of the sides where the fenders bolt up.
The end result would be something like this:
I have no plans to do a TJ/MB grille right now, but maybe I'll do it sometime in the future.
OP
When the grille comes out of the mold, it needs to be trimmed. In the last photo in the previous post you can see how the rough fiberglass overlaps all the edges. These photos show the same grille after it's been popped out of the mold and trimmed.
As I've said before, the grille is designed as an overlay in the same way the factory chrome grille overlay mounts on the factory grille. No need to reproduce the entire core support for mounting the radiator if all that's really needed is a new face over the factory grille.
As I've said before, the grille is designed as an overlay in the same way the factory chrome grille overlay mounts on the factory grille. No need to reproduce the entire core support for mounting the radiator if all that's really needed is a new face over the factory grille.
OP
Testing the fit of the headlight trim rings and turn signals...
OP
In this next series of photos, the new fiberglass overlay is being test fit on a factory grille/core support. Before fitting, the slots need to be removed from the factory grille. That's pretty simple operation accomplished with a metal cutting blade in a jigsaw. Also if turn signals are to be installed (as they are with this grille), clearance holes need to be cut in the front of the factory grille. That's most easily done with a hole saw.
A comparison to a stock TJ grille that has a factory chrome overlay:
Next up: final fitting and bonding it to the the factory shell.
A comparison to a stock TJ grille that has a factory chrome overlay:
Next up: final fitting and bonding it to the the factory shell.
Can you bag the mold and reduce your materials to keep the weight down and increase the strength at the same time?
OP
Doing some preliminary finishing work, I shot the grille with primer.
And in these photos it's being bonded to a factory grille shell using automotive urethane adhesive:
The urethane adhesive sets in a few hours but since I'm not in a hurry it can cure overnight.
The installation, fitting and bonding can be done without removing the factory grille from the Jeep, but it's easier to work with when it's off the Jeep and on the workbench. An easy way to do this conversion is to pick up a used grille on Craigslist, install the new overlay on it and then swap the completed assembly onto the Jeep, saving (or selling) the factory grille that came off the Jeep. The factory grille I'm using for this project I found on Craigslist for about $50 because it was damaged. No problem though, the damage is covered by the new overlay
.
And in these photos it's being bonded to a factory grille shell using automotive urethane adhesive:
The urethane adhesive sets in a few hours but since I'm not in a hurry it can cure overnight.
The installation, fitting and bonding can be done without removing the factory grille from the Jeep, but it's easier to work with when it's off the Jeep and on the workbench. An easy way to do this conversion is to pick up a used grille on Craigslist, install the new overlay on it and then swap the completed assembly onto the Jeep, saving (or selling) the factory grille that came off the Jeep. The factory grille I'm using for this project I found on Craigslist for about $50 because it was damaged. No problem though, the damage is covered by the new overlay
.
OP
I doubt bagging would reduce weight or materials because I designed the layup plan for this part with varying area thicknesses depending on the specific area of the part and the strength requirements of that area, so materials usage is fairly minimum already, but bagging could reduce the potential of trapped air in the layup and that does contribute to strength. As it is though, this part as molded is plenty strong enough for its intended use.
Tray Burge
TJ Addict
Are you gonna make an "angry bird" version?
Could this be done using a chop gun like they use for boat hulls,
or does the grill need to be hand layed
? Just curious as to the ability of a company to be able to produce enough to supply the industry.
or does the grill need to be hand layed? Just curious as to the ability of a company to be able to produce enough to supply the industry.
OP
OP
Yes, although some care would be required. Because this is an overlay, in order to fit properly the area across the top and above the slots can't be too thick while for strength the slots are best made a bit thicker. An experienced chopper gun user can do this with no problem.Could this be done using a chop gun like they use for boat hulls,
I saw this Jk on the Rubicon a few years ago and thought it was kind of cool looking
OP
The adhesive cured overnight so here are few pix of the new grille face bonded to the factory grille shell/core support.
I painted the inside black.
I painted the inside black.
OP
A final test fit of the headlights and turn signals.
OP
Lifting it by one fiberglass slat, it's plenty strong.
Next up: final paint (base color and clear).
Next up: final paint (base color and clear).
I'd pay an unhealthy amount for that grill. It'd look fantastic with an intercooler behind it
Tray Burge
TJ Addict
Bawhahahahaha, I was obviously joking, but the angry response I got was priceless! hahahahahaha
OP