My '95 Satoshi Grille

I've started on a Satoshi Grille mod for my '95 Tacoma LX.
This is a work in progress so I'll add to it as my project progresses.

Let's begin by giving thanks to all who have come before with their excellent Satoshi write-ups. I could not have done this without that valuable information.

Parts list
SS Perforated grille mesh 6" x 36" (customcargrills.com): $9.99 + S&H
Hydroturf SUP Pads Traction Mat 3" Inserts (A&D Discount Perf.): $12.75 + S&H
Rust-oleum Semi-gloss black paint: $6
Rust-oleum Gray primer: $6
Rust-oleum Filler primer: $6
Rust-oleum Clear Lacquer: $6
Bondo body filler: $12.98
Bondo glazing/spot putty: $7.99
Elmers fiberglass material: In house
Elmers resin & hardener: In house
3M 40/80/180 sandpaper: $3.69
3M 400/600/800 wet or dry sandpaper: $5.19
Zip tie mounting tabs: $1.50
Two part epoxy: $5


I started by trimming out the center plastic piece. I used a hacksaw and a jigsaw and trimmed it close to edge. Then I sanded down the edges on the surround.


I masked off the edge of the sides in prep for the fiberglass.


I also masked off the front of the grille for protection from messy resin, etc...


Next was laying down resin/fiberglass/resin (two layers of fiberglass).


While the glass dries I did a test fit of mesh and cut an inch offset from sides with Aviator Snips.




Bondo time, on the edges. "It ain't no good unless you get it all over" as my pappy used to say. Don't worry about globs, it sands off.
I also epoxied some zip tie mounts to the back of the grille.


Painted the grille 2 coats primer, 3 coats black, 2 coats clear.
Cut w/razor and spaced with tile spacers the Hydroturf Snow Camo letters. The turf has 3M tape already on the back.


That's as far as I've gotten to date. There will be more after the sanding stage.

 

Very cool. Definitely one of the most pain-in-the-ass mods I've done lol. Well worth it in the end, though!

 

Just tell me where to send my grill to when you're done with your 95' and you can do my 95'!

 

With zero bloody knuckles I call it a win

It's an easy mod to do, just take your time and know when to walk away.

 

Filler Primer, Sanding & Glazing time, followed by painting primer, semi-gloss black, clear (two coats each).



While I had the grille removed I installed two amber LED's and added wires.

Next I zip tied the mesh to the grille surround w/mtg tabs that were epoxied to grille plastic.

I added the Hydroturf letters to the mesh prior to zip tie install. It has 3M tape already on the back when I purchased this mat mat'l.

And the final install on the truck. Next up is to finish the Raptor LED's.