'03 & '06 Retrofit Satoshi Grille Writeup (Picture Heavy)

[gaterose]

Finally got around to building one of these... This one is primer grey because the member plans to have it painted by a body shop while having other parts painted.

edit- Also, there is a black rubber weatherstrip that adheres to the grille where it meets the hood. I didn't attach that because it'll be easier to paint without it, when installed it makes the transition from grille to hood look smoother. The '03-05 grille doesn't have that strip so I'm thinking some of you might not know that and think the transition looks rough.

'06 Satoshi to fit OEM '03-05 bumper and headlamps

Thanks to [MENTION=72620]A_HuL[/MENTION] for the test fit!

[MENTION=79237]sigepbiker[/MENTION]

 

[A_HuL]

ew whos 4runner? That thing is hideous :lmao:
Oh and i know a bunch of you guys are dying to do the the reflector mod inside your headlight like my driverside......very custom, i will do a write up soon on how to achieve this awesomeness

 

[007Tacoma]

That one was made for th1e swin1e, I plan to start making some that are similar to work with the '03-05 headlights. The grille above will only work with '06-09 headlights. I still have your name on my list (I think you're 3rd or 4th) and planned to contact everyone on my list after I've finished the first prototype.

Matt, If there is still a list to get an 06+ Satoshi for an 03 bumper/headlight 4Runner, I would love to be on it. I was going to see if Homer could do one for me, but I don't make it out to California often. However, my parents live in Kentucky. So, I drive through Alabama with some frequency (at least once a year).

Cheers! -mark

 

[gaterose]

Matt, If there is still a list to get an 06+ Satoshi for an 03 bumper/headlight 4Runner, I would love to be on it. I was going to see if Homer could do one for me, but I don't make it out to California often. However, my parents live in Kentucky. So, I drive through Alabama with some frequency (at least once a year).

Cheers! -mark

I put your name on the list Mark. Hopefully sometime in July I'll be doing another round, I'm already working on 2 right now.

 

[007Tacoma]

I put your name on the list Mark. Hopefully sometime in July I'll be doing another round, I'm already working on 2 right now.

I appreciate it!

 

[NorCalDood]

A_Hul that 05- grill work turned out great. I like the Shirley Fab bumpers that you and Gator are rocking too. I'm considering getting one now as well (between that and the Demello). Is gatorose still making these? Anybody get a grill done by him recently?

 

[SR_5runner]

gaterose, awesome work! I have an 05 and have been following the progress. Just a few questions: Are you still making/selling satoshi's for 05's? If so, I'd love to pm about costs/etc.
Could you elaborate on what I am looking at/ how you constructed the L shaped metal frame in the most recent 30-05 mod photos?
Lastly, could you speak on how you got the correct cut for the grille to match the line of the original 03-05 headlights? Having that gap match properly is important to me, and an awesome voucher for your attention to detail!

Thanks for all the help!

 

[SR_5runner]

Satoshi Details

I need to fiberglass it back together.

I did remove the black piece

emelianenkov, I saw the photos in post #56, but just for confirmation did you separate the lower horizontal bar from the "upside down U" to shorten it enough to fit properly? I have an 05 with the 05 headlights I am wanting to do this on, so just trying to iron out ALL the details before I get goin.

Also, for anyone who has done this, when purchasing a 06-09 donor grille, does it come with the metal subframe? If not where should I source one from?

Lastly, I think I want to use pop rivets/manual rivet tool to attach the plastic grille pieces as well as the altered metal subframe. Do yall think the plastic will withstand the pressure from the "pop rivet" tool when compressing the rivet??

Thanks for the help!

 

[tannerk15]

Would love to get on a list to buy one of these if anyone knows someone that still builds them.

I have a question, which may have already been addressed, but can I build a satoshi grill for an '03 with a grill off an '06? I found a cheap OEM grill that is one of the newer ones and wanted to use this to build one for mine.
I know the grilles are different for these model 4Runner's but the hole and shape seem to be the same.

 

[bd-wheels]

I'm be in for buying one for my 04. Please put me on the list too. Thanks, Bill

 

[VT_Kook]

I don't have as many pics for the '06 grille but the missing process was similar.

First I cut everything out so I only had the upper upside down U and lower crossbar left.



Then I mounted the U on the hood, and trimmed the bottom until the hood would fully close



Then I trimmed both sides of the lower horizontal bar until it would fit inside the U





I also pulled the metal subframe and trimmed it in the same way so that it would fit inside the new shortened grille. After it would fit in the "new grill" and line up with the holes I drilled a hole through each end of the bottom bar and a matching hole in the uprights then bolted it together so I had a new shortened sub frame. Sorry I don't have any pics of this but hope my description helps.

Then I JB welded, fiberglassed, bondoed, & sanded everything back together in the same way as the '03 grille and cut out a piece of expanded sheet (since the gutter guard is too small for the '06 grille hole) then formed it in the same way (only harder because the expanded sheet was stiffer).

Then I bolted on an 80s FJ emblem and this is what I got







Hood release -


These corner squares had to be trimmed for clearance




You can see I preferred the formed grille piece that was "3D" and protrudes from the grille. It can also be done with the mesh flat and recessed behind the grille.



People keep asking so --
Will I do it for you?

Sorry but I don't have time for these anymore (updated 2/21/17)

What did you end up doing with the '03 grill?/any final pictures of it on the car?

 

[emonell2]

This is somewhat unrelated to the thread, but seems like a good place to ask. Do the different year grills mount to the hoods the same way?

Looking to put an 2003 hood on a 2007 and keep the 2007 grill. Couldn't find info if it would all fit anywhere else.

 

[Anonymous4Runner]

This is somewhat unrelated to the thread, but seems like a good place to ask. Do the different year grills mount to the hoods the same way?

Looking to put an 2003 hood on a 2007 and keep the 2007 grill. Couldn't find info if it would all fit anywhere else.

It will not work without modifications to the earlier grille for '06-'09 4R's. You're better off finding a grille for '06-'09 instead of using '03-'05 grille

 

[emonell2]

It will not work without modifications to the earlier grille for '06-'09 4R's. You're better off finding a grille for '06-'09 instead of using '03-'05 grille

I do have a 2007 grille for a 2007 4Runner. Just can only find a 2003 hood in my area. But I just wanted to make sure because can't find the exact answer.

So the 2007 grille does easily mount on a 2003 hood without modifications? And then that hood and grill assembly will work on a 2007 4Runner?

 

[Anonymous4Runner]

I do have a 2007 grille for a 2007 4Runner. Just can only find a 2003 hood in my area. But I just wanted to make sure because can't find the exact answer.

So the 2007 grille does easily mount on a 2003 hood without modifications? And then that hood and grill assembly will work on a 2007 4Runner?

No, an '07 grille will not fit on an '03 4Runner without modifications.

If you have an '07 4Runner and want to use a '03-'05 grille, you MUST modify the '03-'05 grille for it to fit on '06-'09 4Runners. Same thing applies with '06-'09 Grilles on '03-'05 4Runners.

I do have a spare '07 Sport chrome grille collecting dust in the closet if you're interested in it. Shoot me an PM with offer.

 

[TygeT4R]

Where did you end up buying the toyota letters from for your satoshi grille?

 

[ah_nang]

Is it too late?

I plan on doing this mod and have been researching a lot on about the grill former? Any chance I can get you to fabricate one Gatorade? 04 runner with 09 HL swap

 

[porterroth]

Any instrest in Satoshi Grilles for 03-05 4Runners?

I will soon be making Satoshi grilles with raptor lettering for 4th gen 4Runners (03-05). They will be priced at $320 USD plus shipping. Any interest? I will make the first prototype to show the expected look of these grilles if enough interest is shown! Thanks all!:cheers:

 

[thuanvu]

I will soon be making Satoshi grilles with raptor lettering for 4th gen 4Runners (03-05). They will be priced at $320 USD plus shipping. Any interest? I will make the first prototype to show the expected look of these grilles if enough interest is shown! Thanks all!:cheers:

website? pictures? examples?

 

[porterroth]

Any instrest in Satoshi Grilles for 03-05 4Runners?

website? pictures? examples?

The attached photo is the precut grill I will be using for my first prototype. I will be using aftermarket 03-05 grilles to build around which can then be painted in oem paint colours.

I do not have a website and will be operating solely through forums at least for now. Currently I am preparing for my first prototype so by the time it is finished I will have an example of the final product and will be ready to start making grills for any interested buyers.

My account is very new on this forum but as soon as I am permitted to create my own post I will do that so it is easy for me to reach anyone who is interested. For now if you are interested or have any questions let me know so it is easier to judge the intrest in these for me and easier for you guys to know what you are buying.