Edge Grill Build.

[Ranger850]

I'm converting the XLT grill that is currently on m Edge in to a Custom Edge grill. The backstory is, When I got my Edge it had a busted grill, then I wrecked it and Bent the bumper and finished off the grill, I replaced it with '03 XLT Grill. I was able to scavenge a honeycomb Edge grill insert from the JY. When I got home I realized there is a small difference in the Edge vs XLT, and this is why I'm here, to document the differences and the changes I will make to each. The End result should be a subtly different grill. A hybrid of sorts. Pics coming soon...

 

[Ranger850]

I had to remove the chrome XLT insert from the grill. And as you can see, the Black Edge insert and the white grill have the same top piece. The Edge insert basically just snaps back into the grill but the top of one will have to be altered in some way. I plan to figure that out this weekend.
Sorry about the squigglies in that pic

 

[Ranger850]

Bad weather and a non-working pressure washer kept me from getting much progress done, but, I noticed something while I was dry fitting pieces. It seems the Edge insert is more different than I first thought. When you put the two insert pieces on top of each other, from the back, it looks like all the snap/clips line up across the bottom and up the side, the tops are obviously different and this is where I knew I was going to make alterations, but the Edge insert has a "lip" that the XLT does not. So now I may have to re-evaluate what I am going to do. I am fairly capable with a Dremel tool and think I know how I want to approach this, but reality will dictate which choice I make. Which ever is the easiest with less cutting is the way I will probably go.

 

[91stranger]

Can you add a pic of the honeycomb grill dry fitted so we can see what the issue is? I see the lip on the top of the grill but you should be able to take a grinder and grind that down if it is in the way. I would just like to see this to see if it is worth attempting myself.

 

[Ranger850]

Can you add a pic of the honeycomb grill dry fitted so we can see what the issue is? I see the lip on the top of the grill but you should be able to take a grinder and grind that down if it is in the way. I would just like to see this to see if it is worth attempting myself.

Yes I will post a few more pics soon. Crappy weather is slowing me down.
The problem is the Edge lip, it's about 3/4" and the XLT lip is nonexistent.

 

[Ranger850]

This probably should have been my first pic, but here is the XLT grill, before, and I will post a side by side when I am done. as you can see the XLT insert is almost flush with the bezel. The Edge insert is recessed about an inch, this is where my problem is. more to come, weather permitting...

 

[Ranger850]

This is the dry fit for the Edge insert with the clips lined up, there is a gap

 

[Ranger850]

These clips will be rendered useless. the side ones are already broke, so a dremel will take care of the rest. The ones across the top may stay for ziptie anchor points

 

[Ranger850]

This is where the inserts differ. The Edge (bottom) has more places to snap the clips together.
Edit ; Also notice the Edge and XLT have slightly different angles in the bottom corners. The Edge kinda straightens out while the XLT doesn't. This is what creates the gap in Post #7.

 

[Ranger850]

This is a dry fit with the entire lip tucked into the grill. In reality this is the easiest. I could just use a handful of zipties and be done, but I want a little more than just zipties holding it together.

 

[Ranger850]

I will probably use my Dremel to cut away at the Bezel and not the insert, but I get a little anal with cutting straight lines, so it may be a day or two before I post more pics.

 

[Ranger850]

Can you add a pic of the honeycomb grill dry fitted so we can see what the issue is? I see the lip on the top of the grill but you should be able to take a grinder and grind that down if it is in the way. I would just like to see this to see if it is worth attempting myself.

It's probably NOT worth it. I'm a glutton for punishment and insist on being difficult. It would be so much easier to just buy the right piece. Unless ,like me, you just want something different than everybody else.

 

[Ranger850]

Another look at the overlap area. Red is the Grill, Green/Yellow is the Insert

 

[Ranger850]

I also made a stencil or pattern of the Insert, then I marked the grill where the two pieces line up and laid the 3/4" piece on the inside of the grill on my marks.

After masking the cut areas with tape, I drew the cut lines on the inside. I think cutting from the back is the way to go. Idk???

 

[Ranger850]

I made the stencil a little smaller than the actual flange so I don't cut away too much grill the first cut. If ANYBODY has any ideas or suggestions on what I am doing right or wrong PLEASE chime in. I have never done this type of modification or worked with this Plastic material that the grill is made of, and any and all help would be appreciated.

If I EHFF it up too much, I'm just gonna buy and egde grill from Ebay for $60, but I'm doing this even if its for the lesson of learning