Satoshi Build Help

SR_5runner

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I am in the process of doing a satoshi mod on a 06-09 grille for my 05, with OEM 05 bumper and headlights. My plan is to have the mesh bent to a slight radius to match the curve of the 06-09 grille radius and be mounted behind to give some depth to the grille, vs bending the mesh and mounting it flush to the front of the grille. Can anyone lend some tips on how to best put a slight bend into my mesh (ss Raptor style) sheet I have??? Thanks a ton for any help or ideas!
 
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If you're trying to get it to conform to the grille them just putting it on tight will do that. Other than that I can't really say. Mine's flush and I can't picture anything else.
 
If you're trying to get it to conform to the grille them just putting it on tight will do that. Other than that I can't really say. Mine's flush and I can't picture anything else.

^^^Thought about doing this ^^^

My plan as of now is to JBWeld or QuikSteel appropriately sized allthread to the interior of the grill surround, then attach the grille btwn w a lock nut. That way I can remove the mesh to service it if ever need be (ie: repaint, re-letter,etc.)

My concern with just having the mesh flex when tightening it down is that whatever I use to affix the allthread will be too stressed when trying to use as the anchor point for bending.

My other thought was to measure the overall length end to end, then measure depth from the center of the lower bar to the intersection of the furthest inside points of the outside edges of the grille. Once I have those #s, I can make a form to bend the mesh over. Will just need to find items to apply force with that wont pinch the mesh sheet. (I'll try to upload some "plans" once I can get some drawn up)

I don't think the radius is enough to need to account for a significant enough growth or reduction of size in the metal at the "bend epicenter" (for lack of a better term!)

What I MAY end up doing also is removing the curve in the interior side of the grille so the mesh will be flat across, but recessed enough behind the grille to not look out of place against any other remaining radius pieces.
 
I put a bend in mine. If I remember correctly, I bent a lip inward to have to to screw to the grill housing and I made cuts in the lip to allow the flexing needed for the radius. I screwed in the end first and then worked my way down making sure the bend was where I wanted it before I installed the next screw.. does that make sense?
 
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My concern with just having the mesh flex when tightening it down is that whatever I use to affix the allthread will be too stressed when trying to use as the anchor point for bending.

I thought I needed screws but I found that the grille I used stuck when pinched with pliers, but it sounds like you won't be able to do that. So you're trying to mount it recessed like this right? Satoshi Grill Mod - DIY - Toyota Nation Forum : Toyota Car and Truck Forums This might be helpful. I knew I had seen a recessed tutorial when doing it.
 
So you're trying to mount it recessed like this right? Satoshi Grill Mod - DIY - Toyota Nation Forum : Toyota Car and Truck Forums This might be helpful. I knew I had seen a recessed tutorial when doing it.

Yup. That's the exact thread I used to solidify my mounting idea. I wanted to mount it similarly, and that confirmed a few of my ideas! (love when you find something that is such a good match for your ideas haha)

From what I could see, if doesn't look like the tacoma grille has as much of a radius bend/arch as the 4th gen runner does.

I am NOT to the point of trying to figure out the mesh yet, so once I get the frame bonded together, and modified for fit and finish that is up to my liking I will have more definitive feedback for how I will get this part of the mod done.

And yes, I have actually been taking pictures (normally forget the SECOND I start things) so there will be a write-up specifically addressing 06-09 fitment for 03-05 bumper & headlights, with recessed mesh...or at least an attempt at one!!
 
Okay yea I get what you're doing. You'll be fine I think with the bend and stress on the thread.

I'd look for something like the bolts the grille uses (the ones with the rectangular head) because then the jb weld will have a greater surface area to attach to.
 
When building mine I followed that Toyotanation thread that muscarellaw posted above. I did the threaded rods at the top and then drilled holes in the supporting metal piece behind the grill and zip tied via those holes. I posted some pics of how I attached my mesh in my Satoshi thread here: http://www.toyota-4runner.org/4th-gen-t4rs/154757-compiled-satoshi-build-help-picture-thread.html

Theoretically it should work the same with raptor style mesh. If you snug it up to the grill, it should take the shape automatically. You may just need to add more attachment threads than someone with a lighter mesh.
 
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the professional way would be to press it with pressure. You would need to make a mold and the metal needs to be stretched and shrinked in tiny amounts so it doesn't look deformed. you gonna need to male and female template. this will take a lot of work and you could probably make some money off this forum if you did this.

If you want to keep it simple you just gonna have to do it by hand and maybe try some heat. i would also try different relief cuts (slits or triangles) to help the mesh curve. Your gonna have to trial and error it if you don't want to make at least a mold to stretch it around

https://www.youtube.com/watch?v=e2Xp6m_bU2c
 

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