Nice details/pic's...thanks for taking the time to put this together.
Couple of questions:
What kind/type of paint did you use?
You said you put the top along the top edge of hood. So this doesn't scrape or interfere with opening/closing hood?
Lessons learned? Anything you'd have done different if you had to do it again?
Self etching primer 1st. Flat black 2nd. Duplicolor I believe was the brand
Nope, no problems at all. I had to bring it up that far because the screws at the top. If you open your hood and look there is about 3/4" before the hood sub framing would get in the way. The sub structure is what actually contacts the foam gasket under your hood, so the bolt and nylon nut are not in the way.
After drilling pilot holes for perimeter screws, check underside of sub framing and use the hole saw to cut out access holes, not a 1/2" drill bit, I couldnt get my thin wall'd sockets thru. Its really difficult to hold a hole saw steady with no pilot hole.
The hood sheathing is only attached to the cross bracing with a foam glue, no welds. After the cut you can just pop the panels off. I use a razor blade to scratch the foam off, sanded it down and painted it red.
When drilling the 1" holes for cutting purposes, dont drill all the way thru sub structure. You will feel it when it breaks thru the hood. There is one that can be drilled all the way thru and thats the washer nozzle hole. The louver has a slot that fits the JK's nozzle perfectly.
When putting the footmans loop back on, dont overtighten the nuts. The studs break really easy!
nice job! how long did it take w the dremmel?
Not to long, the hood is really thin. Maybe an hour or so.