So I really liked the pictures I saw of the "Satoshi Grill Mod" and decided to do it.
I also recently purchased new headlights, bug shield and corner lights but that will come in another thread.
References:
This guide will help you out in your quest; I didn't follow exactly.
4Runners.org Tech Write Up
4Runners.org - The Satoshi Grill Mod
What I did differently:
* no fiberglass or bondo work; it is IMO unnecessary.
* did not build steel supports for the emblem
* did not build/attach at outer liner for the mesh grill
OLD LOOK
I decided to buy a new grill since the old one was damaged and I am hoping for this mod to last 100k.
The new grill was $82 shipped on ebay.
OLD GRILL & NEW GRILL
Here is the old grill's road damage; there is also some rusting
ROAD DAMAGE
I bought supplies at home depot; you can probably skip the white paint, I didn't use it.
SUPPLIES
On the first cuts I only intended to remove the center piece. I suggest you use a small hacksaw so that you don't risk damaging the (new) grill. The less damage you do when cutting, the less need for bondo/fiberglass work.
1st cut
2nd cut
3rd cut
Cut the grill mesh to match outline
No pics of this step. Simply trace out the mesh using a sharpie, then cut. Beware, the mesh is extremely sharp once it has been cut with sheers; I found this out the hard way.
Polishing Bit
Time to paint the gutter grill. I bought two so that I'd have a backup.
Painted Mesh
Grill Paint 1
[Grill Paint 2 [/B]
/** assembly pics to be posted tomorrow **/
:beer: