Finally got my grills done.
I bought some bulk grill material from DJPhatman a while back. Since then I've been devising the best method for constructing and attaching the grills. Here's what I came up with:
First I cut the material down to size, using an abrasive blade in my hand-held circular saw, one inch oversize in each direction. Then I cut one inch squares from each corner using tin snips.
Then I used my WorkMate and some scrap boards clamped to the metal to bend 90 degrees along each edge, one inch in width.
I placed felt buttons at the ends of each brace, and cut one inch (well, slightly longer, so they could compress a bit) sections of automotive fuel hose to use as standoffs for the two screws I put where the braces cross.
Voila!
Not tested yet. If they rattle I'll just have to add more screws and/or felt.