Just found the photo's that I couldn't find. This shows the cross member assembly trial fitted at the front of the chassis. Thought I also had one showing it before fitting but no sign of it.
Should have mentioned earlier that I had a LOT of help from Iain ( slf-uk ) with photo's and measurements. On one of his numerous visits to John's he mentioned that he had a D-160 and 200 and offered to obtain any details I required. This offer was taken up countless times with Iain dropping everything, day and night, and rushing into his workshop with camera, tape, and notebook. Well, not quite rushing but a speedy response. A lot of the photo's found on the internet didn't show details from the correct angle but a request to Iain explaining what I wanted produced the required result. A BIG THANKS Iain.
Now that the grill surround was made it needed something to fill the hole. The grill was made from 3/4 x 1/2" alloy angle with 3/16" silver steel uprights, threaded 2BA at the top and drilled 1/16" at the bottom for a wire pin. The spacers were from alloy tube. Using the 1/2" width of the angle as the front face with a 1/2" gap between each plus the same top and bottom looked about right. A lot of careful measuring, cutting and drilling gave a good copy of the original. The anti rattle leaf spring at the top was from steel shim with threaded tubes over the tops of the uprights where they protruded through the grill surround. This alloy angle was from a green house which John and I dismantled years ago for a friend of his, transported back to his land, stored behind his shed and has never moved until recently. I saved a good selection of various sizes.
Finally, I just had to give the grill a coat or two of paint, the first item painted, to see what it looked like.