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I looked every where for a new grill shell and gave up. I heard that the ones out there were junk. I checked Dennis Carpenters web site again and there it was OE polished grill shell for sale. They are not cheap $ 550 but I had to have one. When it arrived I was very nervous how it would look and if it was worth the money. Well it is. I just installed it and it fits and looks great. I will post pictures when I figure out how to post them on this site.
DC must have just recently started producing those grille shells again, they supposedly had suspended production about a year ago until they sourced a higher quality aluminum.
That is great news as I have a new one from DC in the box sitting in my bedroom waiting to be installed!! I bought it about a week ago. I have the same style 73-77. I also got the inserts, rubber heat shields, and bumper guards. Got the new bumper from NPD. That is great news, the shell does look alot better even sitting in the box. Montana the fella that I spoke with when I ordered mine told me they just got a memo that day stating DC had 50 in stock.
i know what ya mean berry1234, our grilles must be made out of super rare aluminum! lol lol
maybe Dennis Carpenter should start excepting cores? then they can melt down old beat and bent up grille shells! then they can make new grilles with original Ford aluminum!
i went sanded and polished my grille up, its not 100% perfect, but then if i got a new grille i would end up marking it up anyways, but some day i might end up ordering a new grille for a spare, just in case!
but i will post some pictures of the grille and the truck this Spring, right now its got ice and snow on the truck! its hibernating like a bear for the winter!
also its not 100% done, the truck is about 94% finished its frame up resto that began in September of 2007, but are they ever 100% done!
all i can say, is the wet sanding worked really well, and it took lots of work, but well worth it, i think i started with 1000 wet sand paper, then i went up to 1500, then to 2000, and then polished it up, i think they make 2500 and 3000 grit, if i can get 3000, i will go over it again this spring, and polish it up again,
but it did come out like new chrome after i polished it up! and i even got out some major scratches out, as the passenger side of these grille shells tend to get scratched and dinged up, as previous drivers miss judged the size of there truck, and i assume they grinded into something! but now my passenger side looks just as good as the drivers side,
Fine Rol-lok pads to remove and smooth finish and then progressive 220-400-600-800-1200-1500 wet sanding.
I used a buffing compound after the 1200 to see what needed further sanding and repeated the 1200. Buffed the grille. Wet sanded with 1500. Buffed again and then used another finer buff. Then topped it off with some chrome wax polish.
As for the buffing I have some red rouge and white tripol.
looks great, and mine came out the same, i was kinda worried when i first started, but then it got better and better looking, and i was actually glad i did it,
also on a side note Bullitt390, i see your see your center trim has a screw in it, at the very front of the truck? i don't think my trucks trim has that hole? i know the front trim can hang out, and i was lucky to have one of the original clip fasteners left in mine, i had to create another clip and install it on the one side, otherwise the front of the center trim isn't flush with the body, also when we had to re-drill the holes for the center trim, it was kinda scary! as the doors and front fenders where new, and we had to weld the old holes in the bed, because the previous owner put the clips in bad spots, plus we added more clips to the bed center trim, but drilling into a freshly painted truck makes one nervous!
Fine Rol-lok pads to remove and smooth finish and then progressive 220-400-600-800-1200-1500 wet sanding.
I used a buffing compound after the 1200 to see what needed further sanding and repeated the 1200. Buffed the grille. Wet sanded with 1500. Buffed again and then used another finer buff. Then topped it off with some chrome wax polish.
As for the buffing I have some red rouge and white tripol.
Bullitt, did you just spray on the Easy-Off or did you have to submerse it in a tub? How much of that stuff does it need before you bring on the sandpaper?
looks great, and mine came out the same, i was kinda worried when i first started, but then it got better and better looking, and i was actually glad i did it,
also on a side note Bullitt390, i see your see your center trim has a screw in it, at the very front of the truck? i don't think my trucks trim has that hole?
Oh, totally! The Easy-off freaked me out for a bit. I scored that grille on Ebay for pennies on the dollar and it's perfect except for some weathering due to it's age. But I stuck with it and it came out nice.
I think if i were to do it again (and I do not plan on it anytime soon) I may skip the easy off and probably the rol-lok disks and go straight to wet sanding starting with a 150 or something.
As for the trim, the clips were corroded on the backside, so I just drilled a hole in the trim and then installed some stainless steel screws. Actually the one side was like when I got the truck, so really I just made then other side match.