How to Build a GT Lid (in almost a day) Options

[Eric_Shea]

Damn this site is good...

I started the morning by searching the archives for "GT Lid". I found a great how to that took me to Dave's post on the PP BBS. Great job Dave. I was inspired. Off to the garage.

In building my GT replica I wanted my lid to match as closely as possible. I wanted the two screens to mate together down the middle. This is how my project differs from what I saw on other sites. I left the extra metal (not covered by an additional, original grill) at the back of the lid.

I actually only spent about 2.5 hours on this to get it to what you'll see below. The only thing left to do is to bend the final lip(s) down on the backside of the lid and prep for finishing.

Here's what you need if you care to brave the wilds of creating a GT lid.

* An extra 914 grill.
* Cut-off wheel.
* Tin Snips.
* Sabre saw with a metal blade.
* Die Grinder
* Vise
* Drill
* Body hammer
* Dollie
* Flanging pliers (or something... haven't gotten to that step yet. I'll keep ya posted)

Step 1:

I think this is a fairly easy way to get a GT lid started. I simply used an extra 914 grill but used it in the opposite direction. No "major" bending of metal (at this point). All you'll need to do is cut the mounting tabs off the long side where the two grills will meet. These tabs would get in the way of the tabs on the original grill. By cutting them off and using a "V" notch, the original tabs will be able to mount in their original holes (novel concept). I've also left as many of the (other) original mounting tabs as possible on the grill. More about that later. I used a small cut-off wheel to do the job.

[Eric_Shea]

Step 2:

The tabs are cut out. The picture below shows the notch made by the cut-off wheel.

This is where some bending comes in. The grill mates to the front edge of the lid on the "ends" and stands off by about 1/4 inch in the middle. This is because the ends of the grill are bent in a rather precarious manner. The picture shows the bend on the grill. Notice how you can see more of the "diamonds" on the right side and less on the left. The trick is to flatten the grill out on the ends and "re-bend" in a straight line. The "thick" part of the grill (at the bottom) is molded in that straight line. You need to secure it in a vise along the "thick" edge and bend it back in a straight line using a body hammer.