[Daox]

I worked on the grill block a bit over the weekend. If I do say so, I think its turning out pretty nice.







The first thing I did was tweak the side angle pieces lengths so they were very close (about 1/32nd difference). You don't have to do this, since you could just cut the slats to adjust, but I wanted to. Next, I drilled the holes in the side angles for the rods to go through. I positioned these as close to the angle wall as I felt comfortable so the block doesn't have a big recess in it.





Next up was to cut out the coroplast grill slats. The only trick to doing this is cutting them large and trimming them down to fit nice.







One of the slats will overlap the other. This will help seal things a bit better while they are closed. So far it seems to fit together pretty good.







The next step was getting the steel rods bent up. I calculated with 1" of linear throw (which is what the door lock actuator provides), I would need the arm length (from centerline to centerline of the steel rod) to be .7" in length to get 90 degrees of rotation. I got it pretty close.







The last thing I worked on was the plate that connects the two rods. I just took a leftover piece of the aluminum angle and cut it up into a rectangle. Then I drilled two holes the same distance apart as the holes on the side angles. This plate is what the pushrod will attach to, and the pushrod will then attach to the actuator.