you can take the grill out without taking the bumper off. but you have to user a screwdriver through the front of the bumper and stick your hand up.
heres my diy grill.
Drilled Stainless steel mesh painted black.
http://users.on.net/~mcb21/myphoto/newphoto2/3.jpg
http://users.on.net/~mcb21/myphoto/newphoto2/5-1.jpg
I pressed the mesh between the colored surround and the black plastic backing. you wont be able to do this with the expanded mesh stuff you get from autobahn etc its too flimsy.

