This is a very easy and cheap way to install a custom grill on your 200 series volvo. The only thing I had to buy was the mesh which i found at my local Super Cheap Auto store for $30 AUS.
What you will need:
-Mesh: measure your original grill first!!!!!
-Screws with washers
Get yourself some mesh. Now I know for a fact this stuff is impossible to find in just normal sheets and wholesale and what not. I've been looking for ages and only till recently I found some in Super cheap auto. None of my local hardware store's had any idea what I was talking about. I also found some at Repco. Unfortunaley none sell it in black which is what I wanted.
Take off your grill from you volvo. This is easly done for me I simply took out the knobs on the top by turning them and then pulling them out.
Clean it. So the original grill doesn't show through.
Debadge it. Now I did this by flipping it over and breaking those little plastic things off. I know that sounds very technical but thats what they are. Now don't worry if you do because if you decide not to go ahead with the grill you can always glue the badge back on.
Cut your mesh to size using your wire cutters. If you are using a large piece of metal I recommend folding it a few times back and forth and it should just break off. My '81 volvo had a grill approx 18.5cm x 60cm. NOTE: You may need to trim to fit to your grill. I know I did.
PLace mesh on top of original grill. And then put a screw through the hole where the stripe once was. I only did the top righ and left one's not the where the badge was cause I didn't like the look.
By now the grill should be takening shape except the sides may be flaping out a little. I solved this problem by getting some wire and feeding it through one hole in the top and one through the bottom and tieing it together at the back. THen repeat for the opposite side.
Sorry bout the focus on this one.
Make sure its all fits right and is securly in place as not to rattle or move to violently.
If everything turns out okay it should look a little like this. (sounds I just made a cake)
Put it back on your car. You shouldn't have to worry about ventilation to much as it won't restrict the air flow to much. But if your volvo does have problems with the heat as many of them do then be cautious when attempting to build this grill as not to stop the airflow to much.
And wah la. Yeah I know the car's looking a little dirty alright alot dirty. But I can fix that later.