03-05 Satoshi Grill

[mgson]

So here's a little thread on my satoshi style grill. Let's start from the beginning with my factory grill.

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[mgson]

After removing it it took some time to configure a way of keeping the strength of the grill. All in all I basically cut everything out.

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[mgson]

After cutting everything, you come to realize the grill is now flimsy and on the verge of falling apart. I immediately started reinforcing the areas I cut out with fiber glass.

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[mgson]

After the fiberglass I started planning out my grill insert I picked up some scrap expanded metal locally but sheets of it run about $140 for a 4x8 sheet.

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[mgson]

After cutting the insert to size and filling in the low spots with body filler that's when I initially fitted it to the vehicle. Of course I couldn't wait for this moment. The insert is attached to the grill. They are technically considered a two piece at this moment.

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[mgson]

After all the body filler the next task is to configure the factory secondary latch. After a little more fiberglass the lever for the latch is back in the factory location and the grill is all primed.

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[mgson]

After prepping the grill for paint and color matching the grill to the factory paint here it is!

Just so everyone knows this is not a task for anyone. I'm a certified collision repair technician who has experience in the area of repairs and fabrication. But if any of you have questions on doing this your own and need advice I can help you out. I am also considering this fabrication for sale so let me know if you are interested. I'm located in Sacramento CA

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[Inv4drZm]

Looks great! Not many are brave enough to tackle the 03-05'.

How did you attach the mesh to the backside?

I've been sidetracked with mine for a year or so. Here is what I have done so far:

 

[mgson]

Looks great! Not many are brave enough to tackle the 03-05'.



How did you attach the mesh to the backside?



I've been sidetracked with mine for a year or so. Here is what I have done so far:

I traced on the insert from the visible side of the grill. Then added 2"s of extra material around the traced area. The top portion of the insert I drilled out holes that align with the factory bolts that hold the grill into place. On the bottom I cut out flaps that I bender and riveted to the grill itself. Tomorrow I'll take pictures of it and post them.


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[mgson]

Looks great! Not many are brave enough to tackle the 03-05'.



How did you attach the mesh to the backside?



I've been sidetracked with mine for a year or so. Here is what I have done so far:

By the way your grill looks awesome with the original Toyota grill center piece, I can't believe I didn't think of that before!


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[BackOff]

I started one just before X-Mas, I guess I need to get with it.

Leaving that center piece would make that latch a bit easier.
I used a chunk of the center part to fill the lower cut out badge area, its a different profile.

Liquid 2part plastic moldputty.com and reinforced with 1/8" ABS.


So far...

 

[mgson]

I started one just before X-Mas, I guess I need to get with it.



Leaving that center piece would make that latch a bit easier.

I used a chunk of the center part to fill the lower cut out badge area, its a different profile.



Liquid 2part plastic moldputty.com and reinforced with 1/8" ABS.





So far...

That looks good! Definitely different ways to approach the final look. Is the insert piece plastic?


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[mgson]

Looks great! Not many are brave enough to tackle the 03-05'.



How did you attach the mesh to the backside?



I've been sidetracked with mine for a year or so. Here is what I have done so far:

This is how I attached it from the back.

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[BackOff]

That looks good! Definitely different ways to approach the final look. Is the insert piece plastic?


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ABS plastic


Universal Black ABS Plastic Racing Honeycomb Hex Mesh Grill Spoiler Bumper Vent | eBay

With a Katakana stealth or probably a 1980 style badge from here...was my intention...my first Toyota was a 1980 PU short bed so seems fitting for me.

https://www.indyfjcruisers.com/the-store/red-black-white-badges/

 

[mgson]

These are still available for sale if interested.

 

[benztech82]

Badge-less grill looks really good. That would be on my list for sure after I pick-up my 4th gen in a few days.

 

[Utah_4runner]

Have you found any "TOYOTA" badges that would work with your grille setup? I like the look of that over the standard toyota emblem, and might do something similar to what you've done.

 

[mgson]

Badge-less grill looks really good. That would be on my list for sure after I pick-up my 4th gen in a few days.

Let me know when you are ready to go I can make it happen and color match as well.

 

[mgson]

Have you found any "TOYOTA" badges that would work with your grille setup? I like the look of that over the standard toyota emblem, and might do something similar to what you've done.

No I haven't actually looked in sure some people make them I think I seen someone post about them on another topic.

 

[Propaganda]

Mgson, how much for the grill in white? Thanks!