DIY Satoshi Grill for under $30 (2004 style grill)

today I decided I was going to build myself a Satoshi grill for my 2004 tacoma... I went to Lowes and I purchased all items I needed for $23.93 (I had a dremel, saw, magic markers, and black enamel spray paint etc)

Note: this will probably work for all 1st gens

List of Items:
1. 2 part epoxy - I used Gorilla Glue brand $5.48
2. Dark Gray Spray paint $6.88
3. wire mesh (found in building materials at my lowes) $10.21
4. Dremel
5. coping saw
6. sand paper
7. black enamel spray paint
8. pair of dikes... the tool
9. masking tape

Step 1. Remove the entire grill from the truck, I did not get a picture of this... but it was super easy

Step 2. cut out all vertical pieces approx 1/4" from the bottom of the grill the 12 0'clock strut needs to be cut off (it wont hurt anything)

Step 3. You will need to take the dremel and grind down all remaining plastic until it is flush all around

Step 4. Sand with 80 grit to smooth it all out... then again with 120

Step 5. trace your grill onto a piece of cardboard... then cut it out

Step 6. place cardboard on wire mesh and cut-- leave about 2-3 inches around cardboard

Step 7. trim to around until it fits into the grill use the remaining lengths to wrap around the edges to hold it into place

Step 8. use epoxy to glue the edges all the way around (don't use all of it yet)

Step 9. tape it off and paint

Step 10. remove the large 'TOYOTA' emblems from the tailgate on the drivers side

Step 11. scuff with sandpaper

Step 12. paint with whatever color you choose

Step 13. use remaining epoxy to glue 'TOYOTA' emblems to the grill

Step 14. marvel at your awesome ass grill

Step 15. clear coat

Step 16. clear coat

Step 17. clear coat

Step 18. install the same way it came off...

I will be sure to get more photo's. It took me about 3 hours to complete (excluding dry times) and by the time I was done it was dark and couldn't get a good photo but here are some in the mean time. Also, after trimming the vertical struts I noticed the bottom was solid and the top had gaps... I decided nobody would ever see the top so I didn't fill it with fiberglass...

 

any final product pictures?

 

Interested in finished pics in the sun too. I was eyeing that Lowe's mesh but wasn't sure if it would be too seethrough...
Awesome work OP!

 

Awesome, cool and cheap. Might try this with a donor grill for my 95.5. Did you happen to see any finer mesh? No Toyota emblems on my tailgate (painted on). Was thinking about just spray painting TACOMA with stencils in white. Maybe paint the mesh gunmetal beforehand.

 

I will be doing this soon!

 

Definitely going to give this a try

 

I was also put off by the size of the mesh but it was the best expanded aluminum I could find without ordering online.. I finally have pictures also

Edit: I swapped out the Toyota emblem to the one I pulled off my 2014, not sure how I like it but it'll do for now

 

Hi there. I just picked up a Tacoma a couple days ago, 2004. I was looking for cheap but cool upgrades that I can do when I came across this. If you still have it, can you let me know how it’s holding up after almost 3yrs? Thanks so much. Sorry for the resurrection, but hey, sometimes it’s fun.