Satoshi help - epoxy resin

I'm going to trim it down to about 1 3/4" maybe 2"...

 

Subbing to see how I his goes. About to do my 2014 and was going to just go at it with fiberglass. I didn't even think to think about plastic and fg not bonding together.

 

I was thinking the same, but he's got his truck to test fit it so it's probably fine.
Choosing the slope angle for the sides was a difficult decision for me.

 

I had to redo my '13 because the head light go t in the way

 

- the grill I'm using is actually a dealer take-off (bought it "used"), and I don't plan on tearing my truck apart for test-fitting.

- What are you referring to by "SLOPE ANGLE" ?

 

Subd

 

FWIW, I would not consider opening the hood and removing the grill "tearing the truck apart"
Anyone can have the grill off of a Tacoma in under 5 minutes with a flat head and phillips head screwdriver.
Besides, test fitting your grill design fit prior to finishing it is just a wise choise.
You'll want to check that the sides of the satoshi you are constructing will clear the protruding headlights. The 2012 headlights obstruct the ability to recess the sides straight back - hence the "slope angle".
Hope that helps.

 

I vote plastic weld it. Get a sheet of ABS, cut everything to fit, plastic weld, then body work it.



Fortunately, I was just able to just cut my filler pieces from the scrap leftovers of the grille center

 

You have a 05-11 grill. The 12+ is a whole different ball game as homer could probably contest. The 12+ grill is 10x the butt ache. I used a soldering iron and ghetto welded it. Just to support the bondo

 

well said.

 

I understand that, hence the suggestion of getting a sheet of ABS to cut/shape. Get a sheet of ABS, cut it, and use heat to bend/shape it to fit the missing section.

I just posted a picture of my preferred method - plastic welding.

If you have access to Fusor/panel bond, I would actually suggest that over plastic welding.
:beer:

 

Thanks again HOMER.

Gonna get started on it this weekend.

 

I used the center section that was cut out. heated it with heat gun and pressed flat with wood working vise. then cut and shaped ( again with heat from heat gun) to match corners and welded in with cheap hf plastic welder. worked well. sanded to even out, roughed it up and applied a thin layer of Bondo. Will have pics up when I decide on filler- currently reshaping f-150 honeycomb to fit, but may go perforated sheet or billet....

 

Any progress? Really interested in seeing how you made out. Specifically with bonding the plastic.

 

Used the plastic-repair-kit & short-strand F/G... Everything bonded together just fine, it's solid/hefty and has endured repeated flexing/handling of the piece.

I'm gonna start doing the finish-work on the visible side, & get a piece of mesh today to mock-up the mounting points.

* the F/G "lip" is about 5/8" thick in pic # 2...

 

You've got some work into that sir.
Have you tried to test fit it yet?

 

No test-fit yet, gotta remove some material from the backside of the "lip" (on the sides)...

Got me some mesh though...

 

Side view, shows there's some depth to it...

 

That's going to be nice.

 

Great work. Going to be bad ass