I have a 2012 Rzr 800 and was looking at replacing the flimsy plastic radiator grill with something sturdier. Where we ride in the foothills of the Alberta Rockies we often have to improvise trail sections over saplings and other bushes (it's amazing how much stuff you can mow over, just don't try backing up). Usually all the branches get folded down without issue but I have seen someone's weekend wrecked by an errant branch to the radiator. An expensive branch too.

I know there are stainless and aluminum replacement grills available but they still just clip in on the 2012s and would seem to be easily pushed back into the rad. I think you could bolt one in solid from an older model but I still want full access to the radiator for cleaning (silty mud and muskeg here). I had the deluxe Polaris brush guard so I thought I would make a HD grill there. Here's the result.

Some stainless steel expanded metal, black plastic door-edge trim from Canadian Tire and some 1-1/4" cushion clamps. I used two 1" L-brackets for the bottom edge. Doesn't look too bad and it's very rigid. I would have painted it black if it was just carbon steel. Now all I need is the radiator mount stiffener in case I nail a tree.

Nice work Rob. You should post this in the "budget mods" thread! Lot of action there...

I like it! Great job! And you had better get that Radiator Support done for sure. I like the Thunderhawk one.

I CAN'T FIND THE EXPANDED METAL ANYWHERE!!!!!!! Where did you buy it? I have checked 3 hardware stores.

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2013 RZR 570
3500 Warn Winch
Click and ride Half windshield
60" Glacier II Plow

You're more likely to find it at metal fabricators or welding shops... they might have smaller chunks. I got mine from a similar place.

Looks good, and well-done,BUGBOYONE, and highly functional; I like it! Just fwiw, an alternative to the expanded-metal would be perforated-metal, and the advantage/s would be smaller openings in the screen that would only allow much smaller twigs and stuff to penetrate, and would be more rigid, due to having more structural material remaining in the screen. Just my two-bits.........

Cheers

Edit/delete double-post.

I bought some metal screen that is used as leaf guard I am going to try and make work. I just want to say that this forum and its members have helped me tremendously. Thank you

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2013 RZR 570
3500 Warn Winch
Click and ride Half windshield
60" Glacier II Plow

Good, then you owe us all a beer; where do you want to meet-up?........LOL.

Cheers

I will be in Reno in the next few months

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2013 RZR 570
3500 Warn Winch
Click and ride Half windshield
60" Glacier II Plow

Looks good. May end up using your idea. Very nice set up

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Xtreme Honda & Polaris
740-598-9100

I actually bought some perforated sheet metal today. I have the grill cut and painted and will have install pics tomorrow. The metal is pretty thick compared to the gutter screens.

__________________

2013 RZR 570
3500 Warn Winch
Click and ride Half windshield
60" Glacier II Plow

i completed the radiator guard/protector today. The material is 16ga steel perforated sheet cut with a dremel cutoff wheel. The metal was painted with 3 coats black epoxy high temp paint. The bands are stainless steel zip ties. The 1 1/4 clamps mentioned above had to be special ordered. The zip ties have a tensile strength of 100 lbs. I used 13 of them so i think that will be sufficient for now. I also used the door edge guard from the auto parts store and the L brackets below. I have enough steel to make 4 to 5 more LOL.

Attached Images

image (4).jpeg (194.9 KB, 150 views)

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2013 RZR 570
3500 Warn Winch
Click and ride Half windshield
60" Glacier II Plow

Hey, looks good Tommy. Bring on the sticks.

I threw you some credit on the budget mod thread. You saved me some money and heartache for sure.

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2013 RZR 570
3500 Warn Winch
Click and ride Half windshield
60" Glacier II Plow