I am getting close to finishing my grill.....so what has everyone used as the mesh inside? Ive been through Home Depot and looked at the rain gutter grating...its not wide enough...After I paint it body color I think its going to be a black mesh...any suggestions?

 

Advance used to sell some wide rectangle sheets through APC. Some stores might still carry it in stock. Not sure of the width, but length was plenty for a full size truck grill.

 

Go back to Home Depot and look near the rebar/drywall section. My local HD carries mesh in sheets roughly 3'X5' for $8 or $9.

 

aye mike,
lookin good so far. when i did mine, i just went on eBay and searched for perforated sheet metal. that is unless you wanna go for the traditional grille mesh look. But, i'm gettin tired of my setup, and have started the tedious task of making a chainmail grile... yeah, grille armor . good luck, and cant wait to see it

 

although i personally don't care for any of the after market grilles , or for the ss grille....i think the oem chrome is a big part of the hhr style , and 1 of my favorite parts....but , i do have to say that i like what you've done with yours so far....i don't recall seeing anouther made that way.

 

go all out..find someone with a flowjet and have them cut anything you want..flames..dice..money signs..cool patterns u name it...make it out of stainless or polished alum..piece that size is worth next to nuthin from local steel supply shop..flowjet guy prob a few bucks or beer if he is a bud...

 

I don't care for any of the aftermarket grilles I have see so far, either. Street Scene supposibly has one (no pics of it anywhere though), the SS one looks ok, but I really don't like the crossbar that high up, and it needs modification to fit properly.

 

Did you find any mesh to fit in your grill yet?? Do you have any local fabrication/welding shops near you?? If you do I'd check with them to see if they have any small pattern expanded metal. Expanded metal has like a diamond pattern in it, and it is pretty flexible being that it is made out of thin gage steel, you might even be able to find some stainless steel expanded metal. The regular steel could be painted, powder coated. I dont know if it could be chrome plated or not being thin gage steel.Just a thought I'd put out there to help you with ideas of where to find material for your grill.