I originally wanted a ralliart grille for my car but at something like $400 trade price was a little rich so I knocked one up after work one day. it was pretty simple, i just cut away the grey plastic grille and sanded it up nice and smooth. I found a mesh that was pretty close to the ralliart one , urethaned it in, a quick coat of sable black and bobs your mothers brother.One ralliart grille copy. I checked it next to a genuine one and it looks just as good.
In the process i tried a couple of different mesh inserts. I found that the smaller mesh looks a little classier than the big stuff, which looks a little tacky. Also the mesh looks kinda tacky if its not painted black. I also found some cool fine mesh at an aluminium supplier that i'll use to make my brothers TJ grille. It was off security doors of some kind and the bloke had a whole swag of trick looking mesh. Anyone looking for something different for their grille I recomend giving a place like this a go, its a goldmine. Was also thinking of making a billet aluminium grille for a TE\TF. We make them at work for minitrucks(rodeo, hilux etc) and I reckon it would look good with the para' headlights. Opinions? Its a pretty involved process so will probably take a couple of weeks. I'll post when I'm done.

piccies:D billet aluminium grill could look awesome

Yerp yopur onto somethign champ. I tried making a billet grill. Just a mock-up though. Looked ok but i think i needed thinner bars plus i have no way of welding it. If you can make it work i'll buy one off ya.