Ispiration came from a grille fitted to the gold 3W Brizio built some time ago. They are made by Don Starks company Grille Art in Idaho, however, i was'nt paying $4300 US and waiting 12 months for one...
It took me over 200 hours to build......would i do it again ? Fcuk No !
Material used here is 3/8 and 1/4 316 SS heavy wall instrument tube which i happened to "find" at the right price in the scrap bin on an offshore gas platform i was on at the time.
First i mocked up all the panels in position
Then knocked myself up a Boonger Engineering tube roller to form the 3/8 outter tubing.
The top of the surround was then formed and drilled underneath from a pattern i made with a modified centre drill to accept the 1/4 verticle bars
Then the outer surround and mounting tabs were TIG welded, then filed and sanded with emery cloth, followed by 320 grit wet n dry.
All parts were fully polished before assembly as it would be near on impossible to do once fully welded.
The verticle bars came next, these were fishmouthed at the bottom with a 3/8 carbide burr in a die grinder until there was zero gap, then slipped up inside the top hole and TIG'd from behind so the weld cannot be seen.
I leaned the verticle bars back a little to a standard grille so they run parrellel with the leading edge of the side cover.
Once all the straight 1/4 bars were done, i formed a 3/8 centre bar, welded it in and again filed and sanded it smooth and polished it.
Then came the rest, these bar "pairs" all had different curvature and lengths and proved to be a complete and utter headfcuk...They only needed to be out a Ranga's pube and it was bin it and start again....
And here it finally is. Done !
The 37 lights idea has since been canned for good reason and the grille will be now be fitted to an original steel surround with 36 headlights on my steel 3W coupe one day....
I can fully understand why once is enough. But I guess now you know why they charge $4300 US for them. 
