ok... little update for me. reading this thread made me get my ass in gear and finish up my own grill. Like AadosX, I had the cutting and filling done, but was stuck on the mesh install part.

here's a few pics of what I did in the last few hours.



here I cut out a cardboard guide the size of the hole. I used it to cut the mesh (a cm bigger all around the edge). I trimmed as necessary and bent the outter edge in using a bench vise.



here I used a soldering iron and matches to melt the grill into the plastic. I also melted extra plastic (pieces I cut away eariler) onto the grill and then melted it all together... like spot welding.



here it is assembled and ready for paint. More pics tomorrow!