I joined up here quite some time ago when it became clear I was going to need to replace my 1995 6.5 TD Tahoe sooner rather than later. Ended up with an '06 CRD this past summer that, based on what I learned here, I did very well on.

Anyway, a couple weeks ago I decided I didn't want to do what needed to be done around the house, so decided to make myself up a winter front. Based on all of the searches I did, the only one it seems that is commercially available is the blanket style, that I frankly do not care for. What I wanted was a set of grill inserts as was available for the 90's Chevy 6.5s.

Looking around the shop, I had some scrap aluminum Diamond plate and some PCV trim scraps.

So, I made a quick cardboard template and cut the diamond plate to width and length on the radial arm saw. I used the template to trace out the corners, trimmed them roughly with snips and finished them off with a vixen. Turns out, the openings are slightly different, so each was fit by trial and error for each opening. Last step was easing all the edges with a belt sander.

Ended up with this:



Put a little crown on them to create some "spring."



In the first picture you can see a piece of 1 1/4" w by 3/4" h PVC trim that I cut a 1/4" by 1/4" shoulder into. This created a 3/4 x 3/4 x 1/2d plug that fits snugly into the vertical grill slats. I made a quick run to the hardware to get threaded zinc inserts and 7 1" 10-24 stainless cap head screws. Here are the plugs with the inserts and a quick coat of rattle can black.



The white marks on top are small holes I drilled on a diagonal to use a zip tie to keep them in place in the grill. Installed:



Finally, put the plates on and keep a spare hex in the glove box so I can take them off in seconds any place, any time.





I plan to rework the attachment points over the summer, probably some aluminum stock with threaded holes permanently attached to the back of the grill. I also have some SS baseboard lying around that I might use to tackle the bottom opening.

So far, no noticeable difference, but my T-stat is heading south, so I can't really say until I get an in-line t-stat installed.

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2006 Liberty CRD - the commuter. GDE Full Tq Eco, Samcos, etecno GPs

2006 GMC Sierra Duramax/Allison - the toy
RIP - 1995 Tahoe 6.5 TD
1990 JD 332, yep, the mower is a diesel too

That looks great!! I would leave one or two small holes in it myself. But that's a great looking truck.

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05 liberty Sport Black CRD,GDE trans tune, Stant 13519 thermostat , Samco Hoses, Weathertech mats, segr, K &N filter ,2nd gen fuel head, 2.5 inches lift, JBA A-arms, Roof rack,
99 Camaro Silver LS1 heads, loud mouth, fast as hell and just as fun!!!
It was stock when I got it but now It's mine!!
You only love it if you change it!!

Cool! I like it! I'm trying to get a nice black vinyl one made for my black CRD.

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2005 KJ CRD - EURO TC, GDE ECO-FT, GDE TRANS, Lift Pump(<- hard to install, worth it) = 32+ MPG highway and a great ride
Product & Catalog Director @ IDParts.com (888) 444-7951 sales@idparts.com http://www.idparts.com