DIY: 2012 Satoshi-style Grille Modification

First time poster. Here's a quick pictorial on how I did my satoshi-style grille mod on my 2012 MG DCLB 4x4. (3" lift, Terra grapplers on 18" XDs)



Ok so it is obviously similar the traditional satoshi, but it requires a lot more dremmel work and sanding to be able to work with the contours of the grill (not for the faint-hearted). It is a three dimensional grille ... like a grillcraft at the top and a satoshi at the bottom. The photos should be fairly explanatory. The hardest part (other than cutting into my new grille with no DIY to follow) was all the dremmel work followed by shaping the mesh perfectly so that it fit flush with all of the contours of the lower part of the grille. I know it looks pretty easy, but once you do it yourself, you'll scratch your head a few times trying to figure out how the hell to work with the curves and the 3D nature of the mesh.

I read a lot and learned a lot on TW. I wanted my first post to be helpful.


Step 1: Masking off grille. You can remove the plastic from exterior, but I thought it wasn't worth the effort, plus you loose structural rigidity while cutting and sanding.



(2) cutting off grille





(3) creating mold for fibergalss inlay (this is challenging cuz you have to create a curve that follows the lines of the grille.



(4) Laying down fiberglass "curve"



(5) Bondo time



(6) Sanding the bondo down to be perfectly flush



(7) sanding down the entire cut perimeter to a clean single curve



(8) dry fit



(9) prep and paint



(10) playing with grille sizes




(11) playing with mesh I ordered from customcargrills.com (Hexagon XXL)
(first i bent the top portion at a right angle to hug the upper plastic mold of the grille)




(12) cutting and molding the bottom of the mesh to fit the 3D curves of the grille



(13) securing the top of the grille



(14) securing the bottom (i used a metal rod to reinforce tie downs)



(15) finished grille



(16) mounted grille



(17) mounted photos

 

Excellent job! Maybe one day I will attempt this (with a spare grill of course LOL).

 

Good looking grill! I just don't know if I have the balls to cut up my grill lol. How are the head lights mounted and did you have to move anything?

 

good job dude!

 

Looks bad ass

 

Looks good. Did you color match the grill surround?

 

He has a TRD Sport, they are already color matched.

 

Wow that looks amazing. Great job!! +rep for you.

 

Best looking grill for the '12's that I've seen yet!

 

Nice work, looks good, real good.

 

oh homerrrrrr!? where is that guy!

 

Why is there another thread about the same grille?

 

Think he got started on the wrong foot with the first post and wanted to give it another shot. I am diggin the look of the grill OP. Good stuff!

 

looks sick, might have to try that.

 

How did you mount the lights?

 

#bump.. looks nice, hmmm will i ever have the guts..

 

done it on an 07. looks like to much work for my 12. plus the look has not grown on me yet for this mod. i like it stock.. NIce write up!!! will come back here if i decide to do it.

 

sickness!!!

 

+1... Very nice, very ballsy

 

Great work! It looks awesome. I like the use of the metal rod to zip-tie to. Well done!!!