Peugeot 206 GTI

John's DIY Mesh Grill

John sent me his instructions for building a mesh grill. He did it for about AUS$85. Should work on most 206's

Just spent Saturday making a wire mesh lower grill cover. Only cost $70 for the stainless steel mesh and $15 for the rubber strip.

Instruction for the Grill

Purchase a 1 metre length of woven stainless steel mesh (sheet width is 1220 mm).

I used Aperture 11 mm, Diameter 1.6 mm from Melwire Pty Ltd (Head Office 03 9551 2344). Ask for the sheet to be packed flat - mine was rolled into a cylinder and took hours to flatten out. Give the sheet a good clean as it will be covered with graphite dust. You will need 3 metres of black rubber 9 mm x 6 mm 'U' channel. I got mine from Clark Rubber for $5.50 per metre. You will also need a packet of black cable ties and black silicone sealant.

Using a good pair on wire cutters, cut the sheet along the diagonal. There's enough mesh to have two goes at getting it right. Cut the loops off the side of your mesh, then you can skew the diamond shaped apertures to get the effect you desire. I used a few 100 mm lengths of wire to hold the sheet at the desired skewness, otherwise it springs back to square.

Pop the plastic lower grill out of the car and put it on a table. Lay the diagonal edge along the top edge of the plastic grill and use cable ties to temporally hold the mesh to the grill (starting at the top edge). You will have to drill a few holes out to the sides of the grill to accommodate cable ties where needed. Work your way round the grill trimming the mesh about 2 mm inside the edge of the plastic grill - This is the most critical task so take your time. Near some of the corners you may find short segments of wire that want to fall out. Tape them in place for the time being.

You have to cut off the tow ring with an angle grinder. You could leave it on and cut a hole in the mesh if you want, but I wanted a clean look. Remember to paint the cut end to stop rust.

Run the 'U' channel rubber strip around the edge of the mesh starting at the edge of the number plate surround and 'mitring' the bottom corners without cutting all the way through the rubber. The strip on top of the number plate surround is separate.

When you are happy with the fit, cut the cable ties and carefully remove the mesh. Reinstall the plastic lower grill and fit the mesh to the grill with cable ties starting at top middle. You will be able to reach behind the grill to pull tight some cable ties, but some will have to be fastened from the front, in which case trim the cable tie and push the locking mechanism through the aperture of the mesh to hide it.

Finally use black silicone to finish the mitre joints and to fasten any loose strands of mesh (taped above) in the rubber channel.

John Hales - Sep 2002

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