I spend too much time on kjji myself, not only for tractors, I have an old Bronco II thats gettin pretty rusty so I want another one with a decent body as a parts truck.
Anyway, had an old file on the pc at work to run a louver sample, each opening is an individual stike with the punch, the size of the opening can not be changed but they can be moved and spaced out to match the original # of holes, this particular pc is perfectly square but it can be made to match the ford grill, with some detailed paint work I think it would make a very nice 'custom' grill. Big plus being that this can be done with existing tools we have for the punch. If your interested you can search 'Finn Power Shear Genius', we have the top of the line 2008 model, pretty fancy punch by any standard.
Problem with trying to replicate the original grill is the tooling to create the raised rectangular holes, they arent all the same size so I would need a differant tool for each size of hole, at around $500 each it simply isnt logical. I could punch the holes in flat stock and then add detailed paint to create a very similar appearance, but it wouldnt fool any ford fans.
The outer frame of the grill is all very basic, hands on, time consuming tin bashing, with a little mig welding mixed in. Only concern there is that a metal grill is going to be heavier than the original and should have extra support added down to the frame of the tractor... since I dont currently have any front attachments Im not sure where exactly that can go but Im sure it can be done.
So when looking at the pics keep in mind this was just a pc of scrap I threw under the punch and used an old customer file that just happened to be about the same overall size as the ford grill, if it was redone with new metal and the proper shape with the vents spaced out similar to the oem design it would take on an entirely differant appearance.... and this would be a winter project when its slow at work.