For all the "old salts" that have been making theses screens for years, You can skip this thread, or add any comments you like to improve the process. This was for the 1st timers. As I was going to make a set I decided to snap a few pics of the process.
So I made my own brake cooling inlet duct screens and thought I'd share. I bought a section of gutter screen from Lowes ($5 bucks). I made a paper template of the duct inlet opening, then added 3/16" all around to account for the body thickness. Then I cut out the template and transfered that to a piece of 3/4" oak (Pine will do). This I cut out with a jig saw with about a 15' angle to mimick the shape of the inside of the duct, then I made a duplicate out of the same oak board. I cut out the gutter screen section leaving 3/4" oversize, then clamped the screen section between the two oak "bucks", which I clamped into my bench vice. Then using a small ballpeen hammer I flattened the outside flange all around. Then removed it from the bucks. I then laid the screen flat side down on the bench and using 1/2" line tape I marked a cutting guide to cut off all the excess screen. Test fit shows a perfect fit. The screen appears to be powder coated and can be painted any color of your choice. Mine will be Silver/Aluninum to match the Stainless Steel radiator rock deflector that will cover the radiator.
Happy Trails
Allyn

DSC03628.JPGDSC03629.JPGDSC03631.JPGDSC03632.JPGDSC03633.JPGDSC03636.JPGDSC03637.JPG