I got some requests for material sources:
The stainless mesh came from:
Wire Mesh Filter Disc, Woven Mesh Disc Disk Filters from TWP Inc.
Its a little spendy since you have to buy 10 sq ft minimum but if 2 ~ 3 folks got together you could divide the ~ 82.00 accordingly. I can tell you that the mesh is very rugged and since its stainless, it should hold up well. You will need quality snips to cut it because its pretty hard and you will be snipping a little off here and there to get final fit.
I know others have used expanded galvy steel with good results also and at a much lower price. I know I will have no end of uses for the extra stainless mesh.
Something i did a little different is that i used a door edge guard that was designed for surface mount as opposed to a "U" shaped channel that fits over the door edge. I used the door guard to act as a retainer to hold the mesh in place and hide the cut ends. (see the last photo above in the original post) The structural elements of the grille that I left in place act as a shaped framework to push the mesh against. The edge guard has a very strong 3M adhesive strip that holds it in place really well.
The color-matched grille came from ToyoyaPartsZone. Be sure you know your color codes and confirm what you are ordering matches the expected color as there are discrepancies on the web site parts lists.
The "TOYOTA" emblem is widely available on line but one location is:
FJ40 OEM Grill / Radiator Emblem - JTOutfitters Look around as I found one quite a bit cheaper on ebay. I had to paint the yellow paint in the Toyota letters with a white white enamel paint to make it stand out but I left the chrome that surrounds each letter.
Hope that helps.
There is much more to read by doing a search for "Satoshi grille"
Jon
