My Raptor Satoshi build

Well I love DIY. So I finally got in on a raptor grill batch before they sold out. After missing out on the last 3-4 lol. Luckily found a BSP grill locally for cheap as well. So all I needed next was a real dremel and some sandpaper etc...

Hoping to really get some good progress this week. I have a lot of experience with fiberglass/bondo/sanding/painting/plastic bonding so why not DIY? Plus it's fun

So here was the grill



Cutout the center



I chose to separate the parts to make it easier when I polish up the shell and bodywork and paint the main part.





I did do some small work already on the bottom. Almost got it flat with no filler, but it will need just a tad



And of course the grill!!!

 

I do have one small question about guys with Raptor/Satoshi grills in general.
You see how the top and bottom of the grill are curved? Are you just filling in the cutout on the sides and curving your grill? Or are you shaving down the ends to make the entire grill sit flush?



I'm also curious on the bends in the raptor grill. Are people making "fingers" that actually ft into those bends in the raptor grill? Or just make the entire outer edge of the grill smooth and straight?

 

easiest way is to cut the back flat and fill in the sides. I'm the only idiot that makes the "fingers" as you call them to fit the notches.

 

Yea I plan on making the fingers as well. More time and tedious, but that's why we do it right? Hahah

Any tips on knowing how much to take off of each corner of the grill to make the mesh sit flush? There's about a 3/8" gap in the center of the curve from the mesh to the I side of the grill

 

Just draw a straight line along the top and the bottom and use that as your baseline for the sides.
As they sit stock after you cut the guts out the top and bottom still curve outward and need to be flat

 

Well been working on getting the mesh to sit flat. For the most part it does. A little sanding here and there and it'll be great.

Here's the gaps I'm left with on the sides.





Grill sitting flush



I know I could trim around the entire grill to get the side gaps a lot better. I may, I may trim 1/2" off the entire grill all the way around maybe we will see after I start sanding down the old braces that help the stock center piece

 

Well I worked on the passenger side tonight.
Cut out a scrap piece of plastic, trimmed it fit, I even heated the piece up and tried to shape it the best I could. A straight plastic piece would of left big uneven parts.

So I taped the piece in and epoxied from the back side. Let it tack up then pulled the tape off before the epoxy had a chance to melt the tape to the part











I tried to bend the end of this piece some to make it easier. You can see that taping the front side also kept the epoxy level and smooth on the outside of the grill. This will help with shaping as well

 

Man not much interest in Satoshi grills anymore? Haha

I ground down the seams and epoxy that came through, also roughed up where the OEM braces were, hoping that will help the filler bite better. None of it is thick at all







I need to add a thin thin layer to get the shape just right on the side right there. Yes it being matte or semi gloss black will hide any slight shape imperfections. But I'll know about it

 

Looking good!
curious: how much time would you say you've got into it so far?

 

Uhh, I'd say 6ish hours? I had a crappy off brand dremel to start with. But then just bought a new Dremel from Lowes. So now it moves along faster. Once I knock out the other side, I will work on the fingers. Then I'll really concentrate on shaping the filler and guide coating it. Then just to figure out matte or semi gloss black?

 

@HomerTaco you can see to the left of my name where's the shape is just off a hair. See where the color grey changes from light to darker? I'm not worried about that little pinhole, glaze will fix that



That type of stuff will be taken care of after I rough in the other side and do the triangles.

 

I see - you're going to get the fitment on then add the notches afterwards. Interesting approach.

 

looks good so far

 

Yep, It just seemed a little easier this way. because I can go ahead and mount the mesh with either the stick on zip tie squares, or small all threads, then from each side measure, cut, and epoxy the "fingers" in and they should fit fine

Thanks man. Its tedious

 

Looking good! I always like following DIY stuff.

Matt

 

Primed and blocked the bottom. Very slick now



Also ground down the other side and the last two supports. Had to fix a small part that broke off by a support when I was cutting out the center



See the part on the right? It's replaced now, all epoxied, filled over, and ready to be sanded



I also got the other side piece fit in, bent, shaped in perfectly. It's epoxied in and filled over as well. I will be gone TDY till the 25th. So the few watchers, no more progress till around then. But it's coming along. After this I'll add the "fingers"

Homer, do you use the stick on squares and small zip ties? Or small all thread and washer/nuts? Also what about the triangles? Just epoxy those in on the back side?

 

Man crazy awesome attention to detail. I originally thought I wanted to tackle this project but after seeing all the stuff that goes into one of these grilles i said HELL NO.

 

Don't use those mounting blocks they are absolute crap.
Use a screw on the top two fins to mount the mesh to the two upper grill supports.
For the rest of the mounts string zip ties through holes drilled into the frame.
Check out this thread for pictures on where to drill the holes.
http://www.tacomaworld.com/forum/homertaco/186781-homertacos-satoshi-101-a.html
Do the triangles the same - you'll be happy you did.

 

Ok guys. Got it pretty much finished. Just have to reattach the shell. No it's not grey, it's flat or a satin black with a BSP shell. I may repaint the shell BSP, it was bought used and has a few chips and such

Anyway, I know that you just want pics