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Functional Radiator Protection (grill) for Cheap

This is a discussion on Functional Radiator Protection (grill) for Cheap within the Projects and How-To forums, part of the General RZR category; 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 ...


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  #1  
Old December 23rd, 2011, 02:55 PM
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Functional Radiator Protection (grill) for Cheap

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.






Last edited by BugBoyOne; May 11th, 2012 at 08:37 PM. Reason: moved pictures to PhotoBucket
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  #2  
Old December 23rd, 2011, 03:01 PM
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Re: Functional Radiator Protection (grill) for Cheap

Nice work Rob. You should post this in the "budget mods" thread! Lot of action there...
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Old December 23rd, 2011, 03:07 PM
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Re: Functional Radiator Protection (grill) for Cheap

I like it! Great job! And you had better get that Radiator Support done for sure. I like the Thunderhawk one.
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  #4  
Old February 16th, 2013, 09:41 AM
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Re: Functional Radiator Protection (grill) for Cheap

I CAN'T FIND THE EXPANDED METAL ANYWHERE!!!!!!! Where did you buy it? I have checked 3 hardware stores.
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  #5  
Old February 16th, 2013, 10:22 AM
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Re: Functional Radiator Protection (grill) for Cheap

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.
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  #6  
Old February 16th, 2013, 10:27 AM
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Re: Functional Radiator Protection (grill) for Cheap

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

Last edited by BarRZR; February 16th, 2013 at 10:35 AM.
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Old February 16th, 2013, 10:34 AM
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Re: Functional Radiator Protection (grill) for Cheap

Edit/delete double-post.

Last edited by BarRZR; February 16th, 2013 at 10:41 AM.
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Old February 16th, 2013, 11:27 AM
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Re: Functional Radiator Protection (grill) for Cheap

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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Old February 16th, 2013, 12:14 PM
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Re: Functional Radiator Protection (grill) for Cheap

Quote: Originally Posted by Tlbotts View Post
I just want to say that this forum and its members have helped me tremendously. Thank you
Good, then you owe us all a beer; where do you want to meet-up?........LOL.

Cheers
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Old February 16th, 2013, 02:44 PM
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Re: Functional Radiator Protection (grill) for Cheap

I will be in Reno in the next few months
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  #11  
Old February 16th, 2013, 02:51 PM
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Looks good. May end up using your idea. Very nice set up
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  #12  
Old February 16th, 2013, 07:53 PM
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Re: Functional Radiator Protection (grill) for Cheap

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.
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  #13  
Old February 17th, 2013, 10:32 AM
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Re: Functional Radiator Protection (grill) for Cheap

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.
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  #14  
Old February 19th, 2013, 07:05 PM
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Re: Functional Radiator Protection (grill) for Cheap

Hey, looks good Tommy. Bring on the sticks.
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Old February 19th, 2013, 07:14 PM
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Re: Functional Radiator Protection (grill) for Cheap

Quote: Originally Posted by BugBoyOne View Post
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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