I'd like to put some type of guard on my radiator to protect against rocks & large bugs. On my last van, I used 1/4" steel mesh. It was a PITA to work with.

I remember there used to be some aftermarket materials available, but none of my shops seem to know anything about it. My idea material would be a 1/4 or 3/16 mesh made of aluminum, or a synthetic material. Kind of like stuff I found on a google search at
http://www.wovenwire.com/aluminum-wire-cloth.htm

Does anyone know of a place to buy stuff like this in small volumes? If all else fails, I'll work with my local metal supply place to order something in.

P.S. I plan on mounting the mesh right behind the front grill. It's a bad idea to mount it right against the radiator.

 

I did the cheapey way... bought plastic bug screen like whats on your window screens from my local home depot, pulled the front plastic in front of the radiator and just snapped the plastic back over the front of the screening material. Been like that all winter and no problems and still looks great since the material I got was the black screen color

 

I was worried that regular screen would be too restrictive. I like how easy it is to put in, and it seems to be holding up great. Keep an eye on the temp gage in the first hot weather.

I just posted some pictures on my gallery of the solution. After looking at the grill, I got a roll of the 6" expanded aluminum (for covering your gutters, $4 for a roll). The upper radiator opening was about 10" high, so I stiched a couple of strips together with stainless safety wire, then zip-tied to the plastic frame behind the grill (I really like how easy the center grill is to remove - 3 screws)

I still need to do the lower opening. This is the one more likely to take gravel hits. I dicked around with removing the lower splash shield, but was afraid I would break one of the fasteners. Are these just pressed into a snap fitting?

 

Expanded metal. Can get it in good sized sheets at most any hardware store. Comes in many hole sizes.
Heres some examples I found.......
http://www.marcospecialtysteel.com/expandedmetal.htm

 

I used aluminum screen wire cut to size. I was more concerned with keeping bugs out of the core than rock damage to the radiator but it should work for both. 1/4" hardware cloth would be stronger if rock damage is the main consideration. I would remove the grill, 3 upper screws and 4 bottom clips, about 5 minutes work. That should allow complete access to the radiator and save wear and tear on the hands.

CLPF350