Is there a way to straighten out a dented grill shell? Mine isn't in awful shape, but I would like to see about straightening it out as an alternative to "shelling" out some cash for a better one. Any ideas?

 

Sure. It'll require a few spoons, hammers, picks, dollies, and patience. IIRC, the upper edge is folded so it'll be tough to access. In other words, do the nest you can because without doing something it will be as it is.

 

Fix or replace the front bumper first.. it's making the shell look twice as bad.

.. start somewhere.

 

It's doable for sure but not easy. I had a few dents like that in mine and was able to pound them out. I wasn't able to ge them perfect so it took some grinding to smooth it all out. This of course removes the anodizing and polish but you can't just polish it back, you'll have to remove all the anodizing and polish the whole thing.

 

X2 its doable with ALL those body working tools. Plus you have to remove it completely, so you can easily access the damage from the backside.

You will still have the large cut out (lower/center) section missing? Just going to be that way.

Or you can repair it with a splice in a piece, work over that part over best you can. Then contemplate painting the outer shell completely black.

 

Saving it's not worth the effort. It's anodized aluminum and finding a place to replate is hard due to the size. Probable cost more than a replacement.

 

Yeh, honestly you'd probably be better off finding a replacement shell.

 

Or hammer out the dents best ya can, rough up the outer part so some bondo sticks to it, work that over, then paint black.

Finding a good used outer shell in a JY, is like finding a 5 gal bucket of unicorn tears.

 

If you are anywhere near Missouri you could always go over to Rich's and take his off his truck.

 

https://dallas.craigslist.org/ndf/pt...208425872.html

IS THIS YOUR TRUCK?

 

LOL We are armed and ready around here for "late night parts getting guys"....NVG's and 30 rnd clips are common. lol

My 79 parts truck has already gave up its grill shell with a truck sale. The 79 Bronco complete front clip was sold a long time ago. The other 2 spare front clips are parted out in the dept already.

My 76 parts truck grill shell already sold... I have a good 79 spare in the LOCKED parts shed, but that one is MINE just in case I need one.

 

Here is my project grill shell for my 73. The corner was dented about 2" round and about a inch deep. I used a small body hammer and pick. And filed it and sanded repeatedly until it was smooth. Just have to finish tig welding some deep gouges and polish. So the pics I'm showing is that it's easy just take your time. And be patient. And if you mess up well it was damaged anyway After first hammer and filling and sanding
After tig welding and crack repair
A bad pic of metal needing replacement
After welding and first file and sanding
After final sanding and before polish
Just a pic