This seems like a high quality thread for the Satoshi mod, so if it's not considered a thread-hijack, I will share my experience as well.
I bought a 96 grill on eBay for around $50, it was missing the Toyota emblem which obviously didn't matter. Thought it was a good deal as the majority of these grills were closer to $100. I went to town on it with a wanna-be Dremel tool and didn't bother with the fiberglass/bondo, etc. I'm cheap.
Then instead of the gutter mesh (I didn't like the quality of what I saw at Lowes) I went ahead and bought some black aluminum grill mesh on ebay, got a 12x48 sheet of it for $22 shipped. (Was a "or make offer" auction, asking price $20, seller accepted $16. - love that "make offer" feature!)
I made a cardboard template for the grill then cut it out of the mesh sheet with a nice pair of tin ships. To take it a step further I then used door edge guard in black to frame out the grill, I think it gives it a slightly more polished look.
To attach grill insert to grill I simply used a little bailing wire, attached at three points, we'll see how it holds up. I also attached the TRD emblem with the bailing wire (only visible up close.) The 3M adhesive on the back didn't want to attach well to the mesh, even with clamps overnight on it.
I'll try to upload some pics here in next post..
