[Dr Quail]

How do I build a jig to weld up a copy of a front grill in stainless? 4 horizontal bars framed in but the grill moves out at a slight v shape in the middle. Top extends out over the bottom of the grill? Should I mock it up in wood first, etc. Thanks, jw

 

[pasadenahotrod]

Use wood to make the upper and lower "plates" for the grille opening. Make cardboard templates and cut from them. Make templates for the side curvature of the opening and cut wood patterns from them. Assemble all four pieces in the grille opening. Use angle brackets and wood screws to secure them together, making sure the assembly is removable from the opening.
Now sight down the opening from the top and sides to mock up the curvature of the bars with steel rod or panels of wood mounted vertically in the opening.
Once you are sure your pattern is good, remove and make up perimeter structure for fit into grille opening.

 

[Dr Quail]

Thanks for the start, what do you think of casting in cement/plaster of paris with grease as a release agent for the original piece. then fabricating pieces to fit the mold, angles, etc.? Best, jw :welcome: