Protective aluminum mesh for the radiator

This modification is one I have to attribute to some of the local builders. Not only does this mesh cover protect the radiator, I also think that it adds a different look that is aesthetically pleasing as well. Here are the parts needed to do this modification:

Pegasus Auto 3641-24X36 Medium Mesh Stainless, #6 x .035 Wire, 24″ x 36″ Sheet ~$50 shipped
Snap Fastener – Quick Release Fastener – Clip A-1 Zinc Plate 1-Hole Design $13.99
8 x 1/2 in. Wide x 1/16 in Thick x 36 in. Long Aluminum Flat Bar ~$2.97/ea
Aluminum Blind Rivets Bulk (#4-4) 1/8″ Diameter x 1/4″ Grip ~$23 (or us some from your kit!)

The goal is to get the mesh to cover the radiator fins while keeping enough rigidity to ensure the mesh stays in place. The aluminum bar is used to create the ‘frame’ of the mesh, and the rivets hold it all together. The stainless mesh, comes in a flat sheet – and they don’t recommend bending it as it will deform. My measurements are 22.5″ wide by 20″ high. After creating and mounting, I’d probably adjust the height to 19.5″.

**This is a great time to have some thick gloves and your Wiss aluminum snips.**

Since I don’t have a drill press, I tried to take my aluminum bars and keep them aligned. First, I’d drill a central hole then add a cleco to hold in place. Then used some zipties to hold the two bars together to keep the x, y, & z axis aligned. Worked pretty well!

You can see the frame coming together, all held by clecos at first – next up was the rivet gun.

Now you can see my protection before (cardboard), and the nearly finished result.

This last pic shows the ‘sandwich’ of aluminum, mesh, aluminum. I needed a mount for the bottom and found a few ABS spacers in my parts bin. I found 2 aluminum screws, nuts, and lock washers. Everything is snugged up tight now and ready for action!