need to build speaker grilles

[leanburn]

i have given up on trying to find a set of outside speaker grilles on a 3 speaker dash, the set i bought have way to much curve and i have found a few more that are the same, way to much curve. so i'm going to build something but not sure how and what. i'm not worried about looking stock but i definately want them to look clean and that they belong there. a friend had a brain fart and suggested to use a thin steel plate [ 16 guage maybe ] , cut to fit and simply drill a bunch of holes in it. this sounds way to easy so i'm looking for more ideas.
 it would be nice to still get some small speakers in there still, anyone have suggestions?

[Bullitt-]

http://www.chokes.com/Plastic_Grill.htm

[leanburn]

have you used these before. i assume they would easily bend to the shape of my dash. those are probably the ticket, thanks.

[Bullitt-]

have you used these before. i assume they would easily bend to the shape of my dash. those are probably the ticket, thanks.

Never used them but at 3" I doubt much bending would be needed... I'd remove some foam from under the vinyl & let them recess down as far as I could.

 Another thought is the late 70-s - 80s GM cars like Monte Carlos had a thin plastic trapezoid grill that might be easy to find.   

[duodec]

You could check a craft store to see if they have a molding kit for molding plastic.  User your too-curved ones as a reference to make a mold, and make a new set in plastic (plast-aid or something similar).  Even with the curve in the mold the plastic parts should have enough flex in them to allow use.

I'm certain you'd have to hand-work the back side of the plastic copies to fit; I don't know if the craft-type kits can do both sides, but if you search you might find something that can for not too much money.

[Justins72]

If you do decide to go the mold making route there is a video that shows how to make a two part mold that way you can mold the back and the front for a close to perfect mold.  They also sell all the supplies you would need to make the mold.

heres the site with the video.
http://www.tapplastics.com/info/video.php#video26

[the_engineers]

I bought a 2' x 2' sheet of perforated steel at my local home improvement store to use as a spark arrester on a burn barrel.  It might give you the look you're after.  They had several styles in brass, aluminum and steel.