1st Gen Pseudo Satoshi Grille Assembly

here's the part that has taken most of my time; eliminating the ridge/seam between the outer (frame) piece and inner (grille insert) piece of the assembly...

 

any updates?

 

Sorry for the build-up guys...I had to work all last weekend, and haven't been able to touch the grille since my last post. I'll update this thread when it's done.

 

cant wait to see how it turns out!

 

So bkeith, I am curious if it is critical or even necessary to modify the bottom part of the original grill opening with the fiberglass. I was looking at mine, and it seems like you could just lay the new grill material behind the original grill frame without building up this extra material. Would this not work? Is the grill material too rigid to flex/fit flush against the back of the grill frame?

EDIT. Oh, and now going back to the pix, I see that you cut out the original grill's vertical bars around their bases, leaving a square cutout in the surroundging grill frame at top and bottom that had to be filled with something, and that was another thing I was wondering...it looks like the vertical bars could be cut out just above/below the grill surround and the remaining material just ground down or sanded flush (and thus not creating the large cutouts that need to be filled). Would this not be possible? Am I sniffing too much epoxy?

 

Mmmm...the sweet smell of epoxy. This started out as a deeper-dish satoshi. Thus, I fiberglassed "back" further than the original opening in an effort to create the deeper dish. This will end up as a non-deeper-dish satoshi, as I could never get the fiberglass even/level at the back; therefore, I will be trimming the added fiberglass back to the original opening depth.

You are correct: If you're careful with initial "fin" cut-out, you should be fine w/o fiberglassing the bottom of the opening.

 

what happned to all the pics im curious to see them. and wonder if he ever finished???

 

wow...stumbled across this thread...so, it ended up looking like sh!t, and i ditched it. :O

no longer interested in satoshi mod. sorry fellas.

 

true...this project got away from me...could've been cool.