Kenworth T800 Grill Dimensions and Hood Variants

[MikePhua]

The Kenworth T800 and Its Versatile Design
Kenworth introduced the T800 in the late 1980s as a rugged, multi-purpose truck platform tailored for vocational applications—dump trucks, mixers, lowboys, and heavy haulers. Unlike the long-nose W900, the T800 featured a sloped hood and modular chassis options, making it ideal for fleets that needed maneuverability without sacrificing power. By the early 2000s, Kenworth had sold tens of thousands of T800 units across North America, with strong adoption in oilfield, logging, and municipal sectors.
Kenworth, founded in 1923 in Seattle, built its reputation on driver-focused engineering and durable construction. The T800’s popularity stemmed from its adaptability: multiple hood lengths, axle configurations, and sleeper options allowed operators to tailor the truck to specific tasks.
Terminology Annotation

• Grill: The front panel of the truck’s hood, typically made of aluminum or stainless steel, allowing airflow to the radiator while protecting internal components.
  
• Medium Hood: A hood variant with a shorter length than extended or long-nose versions, affecting grill size and engine compartment space.
  
• Square Inches: A unit of area measurement used to describe the surface size of the grill opening.
  

Understanding Grill Dimensions Across Hood Types
The T800 was offered with several hood configurations, each affecting the grill size. The most common variant—the medium hood—features a grill area of approximately 1,430 square inches. This measurement includes the open surface area available for airflow, not the total panel size. Extended hood versions, designed to accommodate larger engines like the Cummins ISX or Caterpillar C15, have proportionally larger grills to support increased cooling demands.
Typical grill dimensions for the medium hood:

• Width: Approximately 36 to 38 inches.
  
• Height: Approximately 38 to 40 inches.
  
• Surface Area: Roughly 1,430 square inches.
  

These dimensions may vary slightly depending on aftermarket modifications, bumper style, and whether the truck has a winter front or bug screen installed.
Comparing to Other Kenworth Models
Operators sometimes seek grill replacements from similar models. The Kenworth T450, for example, shares visual similarities with the T800, but its grill dimensions are smaller due to a narrower cab and shorter hood. Attempting to retrofit a T800 grill onto a T450 may require bracket modifications and trimming.
In one case from Alberta, a fleet manager retrofitted a T800 grill onto a T600 after a collision, using custom mounts and a modified surround panel. While not factory-spec, the solution provided adequate airflow and preserved the truck’s operational integrity.
Material and Finish Options
Kenworth grills are typically constructed from:

• Polished aluminum: Lightweight and corrosion-resistant.
  
• Stainless steel: Durable with a mirror finish, often used in show trucks.
  
• Powder-coated steel: Common in fleet trucks for cost efficiency.
  

Operators in northern climates often install winter fronts—vinyl covers that reduce airflow during cold months to maintain engine temperature. These covers must match grill dimensions precisely to avoid flapping or airflow restriction.
Replacement and Aftermarket Considerations
When sourcing a replacement grill:

• Verify hood type and year of manufacture.
  
• Measure existing grill opening and mounting points.
  
• Consider airflow requirements based on engine and application.
  
• Choose materials suited to climate and operational wear.
  

Aftermarket suppliers offer custom grills with laser-cut logos, reinforced frames, and integrated lighting. While visually appealing, these may require additional support brackets or electrical routing.
Recommendations for Technicians and Fleet Managers

• Always confirm hood variant before ordering grill components.
  
• Use OEM part numbers when possible to ensure fitment.
  
• Document modifications for future service and resale.
  
• Inspect grill mounts and radiator supports during replacement.
  
• Consider airflow impact when installing bug screens or winter fronts.
  

Closing Reflections
The Kenworth T800’s grill is more than a cosmetic feature—it’s a functional component tied to engine cooling, aerodynamics, and structural integrity. Understanding its dimensions and compatibility across hood variants ensures proper maintenance and customization. Whether restoring a classic hauler or outfitting a fleet workhorse, the grill remains a defining element of the T800’s enduring legacy.