Thanks Moparfinman. If you look closely, you'll notice that I had to make the bottom of the shell first, as it was rotted away. The insert is all made out of 1/8" cold rolled steel. I considered making it out of stainless, but for the car I'm building I wanted a painted grille anyway. Stainless would have been a bitch to work with, because it pulls like a ******* when you weld it. I ended up brazing all of my welds, since brazing doesn't pull much when it cools.
Anyway, there's about 120 feet of rod. I made the perimeter first, and then laid out all the rods and spaced them with 1/4" nuts (standing on edge). I had my helper hold and keep an eye on everything and just worked my way around the outside. I added the two stabilizer bars - partly for looks, but they also stiffen the shell up nicely. I think it only took me part of a day to do it completely.
Total cost? Probably $30 and a days worth of .... fun! I enjoy this so much I think I should pay myself!
Good luck if you do it yourself. For the cost, even if it doesn't turn out, you're not out much.