Need to try and get a better method to reattach the grill to the bod. Any ideas?
Fought with it when I painted my grill too. I don't know what year you have but on '03's (and probably the '02's an '04's as well), if you remove the clips on the body and attach them to the grill, the grill will then just snap back in place.
I agree it's a real pain to and do the replacement in the reverse order of the removal. But, like I said, remove the clips from the body, attach them to the grill and then put the whole thing on the truck. It will just snap in place. Real simple like.
HTH!
-G