Time for many thanks to Radian.
He reached out and offered me a grill that he had littering up his shop. A little FedEx and a little PayPal later and the grill arrived in excellent shape - very nice packaging job, Tom!
The grill was a little long and a little wide.
First I needed to square up one end. So, I did what I've done in the past when cutting grill material that has worked very well....
I clamp the grill between two pieces of scrap BB (that has a straight edge of course). Then insert a fine tooth blade in my Bosch jigsaw (cuts like buttah). I use the edge of the scrap as my guide and just cut along the edge while everything is clamped up good and tight.
Before.....
After.....
Then had to get a longer piece of scrap for the vertical cut.....I cut both dimensions 1/8" short of the inside measurements of the cab.
After finishing the cuts and putting it in the opening, I noticed that it was going to be hard to align the hole properly on the piezo side because they are really close to the edge. So, I clamped it back up and took off an addition 1/16" or so to give me a little more wiggle room. I like the fit now.
It's always a bit of a struggle deciding how to attach grills - especially with so little room for the screws. No way to use small rubber feet as standoffs - so I came up with a different approach.
I found the thickest old guitar cable I had laying around and pulled out the interior cable and ground, leaving just the rubber jacket. Outside diameter is big enough to not go through the holes in the grill and inside diameter is big enough to accept the screws.
I was going to use pan head screws, but I only had some in 3/4" length and that just isn't quite long enough. I have a bunch of the cabinet screws that came with the OT and T39 kits from Leland years ago. Turns out that the bevel head fits perfectly in the grill holes, so that's what I'm going with. I cut the rubber jacket down to 5/8" lengths - that will be a good offset and still leave plenty of bite from the screws.
Last piece I needed to complete the build was some foam backer for the grill. In the past, I picked it up from Wal-Mart - it's just foam filters for window AC units.
However, Wal-Mart, Home Depot, and Lowe's all think that Air Conditioning is a seasonal thing ...... ya' gotta' be kiddin' me! We're in Texas!
So, after spending a morning driving all over town, I came home and ordered 3 of 'em from Amazon....which I should have done yesterday, because they would have been here today. In case anyone is wondering - it's the Frost King brand and it comes in 24x15 pieces....I'll have to do a little splicing, but I did that back with the WH10s years ago and it's invisible.
Anyway, hopefully that shows up soon and I can button it up. Then it will go outside for some EQ work.
Stay tuned....