Hi Barth. For your grill, once you have ensured the flow is unblocked beforehand (second cab? 4" hole? huh? I will just assume you know what you're doing in that dept. Hoosier's airflow thread is the place to learn), your 6" exhaust equals 28.3 sq inches. So to follow the dummies guide to intakes (2x) you will need your intake area to be 56.6 square inches of free flow.
We need 56.6, plus the grill will be blocking roughly one third, so we want 56.6 + half of 56.6, which is 84.9 sq in. You need 84.9 sq in of my grill to have 2x intake. Type this number into a calculator and hit "sqrt" and it gives us 9.2. Your grill, using the same fin thickness, and spacer thickness as mine, needs to be at least 9.2" x 9.2".
Let's look at your 5" restriction which is now causing you problems. We take the 84.9 (total grill size needed) and divide by the restricting dimension. So 84.9 divided by 5" and it equals 16.98 so lets call it 17. Your grill can also be sized 17" x 5".
I always go as large as I can with intakes as long as it doesn't drop negative pressure enough to allow smell to leak out.
These calculs are good but ingore the size of the room!?!?! According to your calcul...I would need a same intake size for my 6 inchs fan that have 424 CFM and my 6 inchs fan that have 309 CFM. Both are same size but doesn't have the same airflow...! You sure those calcul are good?