Has anyone else done this before? I really want to do this for my next project, and would love some input on how you guys have done it, if so.

Here's an example:

This plastic piece in the middle of the grille, I want to remove and just make an all-mesh grille, because I think it would look SO much more aggressive that way.

 

You can't remove the steel reinforcement bar without significantly diminishing the crash worthiness of the car.

 

What he said. You could, however, try to make a smaller version of the middle piece.

 

Nah, just make the faux X piece.

 

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I'm not removing the brace, simply the plastic on the grille. And maybe paint the crossbeam to match the car or grille?

 

even if you remove the plastic and make it all mesh, theres going to be the giant cross beam sitting right behind it, not looking much different.

 

If you just remove the plastic, you will be exposing the styrofoam piece that is there, as well as at least 1 airbag sensor to the elements.

 

I think it'd be more than durable. If you brought the mesh flush with the front of the bumper and painted the crash bar black, it wouldn't stand out. The mesh would hide the bar, and youd have to be looking at the car from the very front in order to see threw the mesh.
wrap the mesh under the chrome ring kinda idea. good luck,