I have done a search for any pics or write ups of a satoshi mod on a 4th gen but have not come up with anything.

Has anybody done or seen a satoshi mod on a 4th gen?
The bottom bar of the stock grill looks like it would cause some problems.

I have seen several X-Runners with recessed grills and they look amazing.
www.xr-underground.com


DIY Mesh Grill is complete but ready for minor tweaking

Comments, suggestions, questions, etc. encouraged and welcomed!

-J

I havent seen it done to a 4th gen. but Id love to do this http://forum.ih8mud.com/80-series-te...mod-style.html

I have been thinking about this mod non stop and I think what I will do is create a new grill from scratch in this manner:
1 put plastic over the stock grill
2 put spray and foam over the plastic
3 remove the stock grill

now I have a form of the stock grill

4 fill the new tray with fiberglass, let dry
5 remove the new fiberglass grill
6 bond where needed
7 remove horizontal bars from stock grill
8 bondo/ fiberglass more
9 let dry
10 paint

this is the first time I will be working with any if these materials, have I overlooked anything obvious? Any tips from experienced users?

Thanks for any tips, advise or pics!

Good writeup #1
Good writeup #2

FWIW, the '03-'05 grill is going to be a little harder to work on as it is a lower profile design. The '06+ have a thicker grill surround that will be easier to work on, especially for a novice. I have actually been looking ito it as well but haven't come up with a surefire way to make my '05s grill look as good as the Tacoma's in the link above.

Also, I have seen a custom one on the 120 forum and here is a link for a replacement grill that is about $600 too rich for my blood.




They can be had here as well.

i started this on my 08 4Runner grill right after i picked up the color matched. After this test fit, i decided not to continue. bronchogg is right, pretty easy for us 06+ folks.

looks nice on the black runner....

In my research I came across that grill. I think flipjin has one, and i followed the links from one of his posts.

I agree, this is about 600$ more than i am willing to pay.

So lets say i basically create a custom fiberglass/bondo grill from scratch...couldn't i just reinforce it with a steel frame on the inside?

When i start this build I will document the steps and contribute something to the forum

please keep us posted

I have been mulling the whole process over in my head and this will be less of a traditional satoshi mod and more of a recessed grill mod.

i'm going to pick up the supplies this weekend and start planning it all out.

measure twice and cut once right?

I will be doing this same grille mod shortly. I ordered a color match limited grille and when it comes in im going to mod my chrome grille first. If its a success I will mod the color matched. Im figuring the second time around will be a cake walk! Good luck and keep us posted with lots of pics!! I'll do the same.

Have you had any luck with grille material? I installed my color match grille today, and im going to get started on my mod this weekend. Still trying to find the right looking mesh! Any suggestions?

I bought some fiberglass and resin on Sunday but i caught something so I haven't made any other progress. I think my first step is going to be to fill the gap behind the chrome bars because I believe they are concaved.

Here are progress pics of the grill I ended up creating for my 2005 t4r.
I could not have done this project without the help of my father, whose hands you will see in some of the photos

Tools Needed:
10mm deep socket
philips head screw driver
tin snips
needle nose pliers
hammer
your choice of paint
masking tape
drop cloth/news paper

suggested:
vise
grinder
safety glasses
gloves


Step One:

Pick out an appropriate material. I bought an 8'x4' sheet of perforated galvanized metal for under $8 at Home Depot. In retrospect the metal is a little thin but perhaps many many other layers of paint will resolve this.

From 2009

From 2009

Step Two:

Create a paper template/stencil to guide the cuts. Something to remember is that the grill had a slight curve, and if you use the brackets from the stock grill you should compensate for that curve, although I did not encounter any issues specific to this. I would highly suggest being generous with your cuts. You can trim as much as you want later.

From 2009

From 2009

Step Three:

Size your cut out against the the gap in your hood. You may notice rubbing in some areas, which you would want to trim away. Please be aware of the "grain" in the perforated metal. My grill has a slight angle but it doesn't bother me too much.

From 2009

This is all I can do for now. I will update after work.

looking good, and looks like this is going to be a great write-up

Step Three (continued):

From 2009

Attach the bottom frame from the stock grill.
A method we used with the grill was to curl the ends. This kept the sharp edges from being too dangerous not only to skin but to your paint!
We had the benefit of a vise, but we also employed the use of needle nosed pliers to get a really tight curl. The vise worked fantastic for a very straight fold and curl.

From 2009

From 2009

At this point you should have accomplished the following;
1. removed stock grill
2. made a template of the opening where stock grill used to be
3. transfered template shape to perforated metal
4. cut your new grill out of perforated metal
5 (optional but suggested). fold and curled the flaps that touch the light housings, and the bottom of the new grill.

Step Four:
Prepare the hood for the new grill.

Place your new grill where it will be mounted. Mark where you will have to tin-snip or drill holes for your mounting screws. We opted to not use the mounting holes on the top corners because they were recessed too much. I felt they would create a really distracting hump if used, IMO.


Mask the following:
Hood (above and below!), Fenders, Bumper, Engine Bay.

From 2009

From 2009

The stock grill is mounted to a lip beneath the hood.
Because the perforated metal is fairly transparent, we painted the lip the same semi-gloss black that the new grill is painted.

Remove the bottom frame from the stock grill. Paint this frame with the same paint as the lip of the hood and the new grill.

Paint your new grill. This is pretty straight forward. If you made it this far with the mod I trust that you can spray paint without a visual :P
Just remember that there are flat surfaces from nearly every angle. I spray painted and re-spray painted about 6 different times. Spray from above, below, left, right, straight ahead and most importantly from behind!


I will continue with the final steps after i watch tonight's Heroes episode