Click the pictures for a larger version.

I made around 7 of these grilles before I finally was happy with the last one. These pics are mostly from grille numbers 5 and 6 with a few of number 7 thrown in. The process was the same on all of them. With each grille, I was able to work the copper over the form to tighter tolerances each time.

One side completed. Onto side two!

Second side pieces cut to shape and bent as needed.

You can never have too many clamps.

Here is the lip down the sides. You can also see the reason for that .064" thick strip that I put in a few steps back.

Cleaned up and it took a trip through the pickle tank. Interestingly, it turns the brass a copper color. Must me something in the water. LOL.

Another view of the lip. I was surprised on how straight it came out.

This is an interesting picture. The grille on the left is the first grille that I made in 2008. I ended up taking some time off from the build because school was getting too hectic and I also converted my lathe over to CNC. The one on the right is much higher quality. It is even more so in person comparing them side by side.
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