Thanks for the details. I'm tackling it this weekend
Basically what I did was go to home depot and get some gutter guard and black spray paint. I got the grill and cut of all the honeycomb inside, as far as i could go, then I got the dremel out and dremel'd it as far as I go go to make it as smooth as I could, Then I sanded the entire this to smoothen it out. I put the gutter guard on the back of the grill and cut it leaving about a 1/2 extra room around it in order to bend it into shape. I bent it into shape using a small hammer and a piece of wood to get a good shape that would fit on nice.
I just came upon your DIY grill post again...i plan on doing this within the next few weeks...is there any way you have a couple pictures of the process or any pointers, anything to help before i dive into this project