someone have any insight as to recommended hole diameter and sheet thickness? i looked up "perforated" on http://www.mcmaster.com/ and got quite a bit of choices.

 

If you like the screen on the XKR, go measure it! I think I'm going to b/c in all the pix I've seen, it's just about perfect. Actually, I think it's more like a screen than what you're talking about.

Have a look:

 

i was thinking more like the grille of the GM SUVs or better yet the little accent that the SLKs and the M class have in their grille and bumpers

 

I hear where you going, but the metal can only be sheetmetal thick, less than a millimeter thick. I has to be sandwiched between the outer grille and the plastic base, then if you want it it be flush with the outer grille rather than bulging in the center, you have to cut out the plastic where the acura logo would normally go. one more thing, if you have chrome or polished steel, what's behind the grille will look more prominent than if the grille was black. I tried both colors and I had to paint what's behind the grille black. I also had to matte finnish the material, because at night, there where way too many things going on in terms of bends and waves in the finnish making it look cheap. it did look hot during the day though. Try radiator grilles from Home Depot or local hardware store.