I did a search before this post on custom grilles but didnt find an answer. I want to letterbox and mesh my 01" TJ grille, cutting out the current plastic seems easy enough, but I'm not sure what to do around the plastic clip holders which are also in the part of the grille I want to remove. If I put the mesh in front of that clip it seems I would have to shape the mesh for each side of the grille instead of simply riviting it across the back of the grille.
Any suggestions would be appreciated.

your best bet would to send DVS a pm on how he done his one
or if i can find a thread on it i'll post it up for ya

Or ashneel as he has made one aswell

Search for "grill" instead of "grille", and you'll find plenty. :D

Havent seen many tj letterbox grills done -would love to see pics when finished.

Would be pretty hard to 'letterbox' a TJ grille as there's no frame at the top and side.
Plus for the passenger side half you'll also need to account for the bonnet lever.

Classiest and nicest look for the beak nose is the Verada grille... but I'm a biased KJ driver. lol