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Grille Writeup - No bondo/glass required

Discussion in '2nd Gen. Tacomas (2005-2015)' started by TX Tacoma, Jun 12, 2009.

  1. Jun 12, 2009 at 8:19 AM
    #1
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    I've received a few questions about my grille so thought I'd do a write up on how I made it.

    This is in no way 100% comprehensive, but I'll try to cover all the main steps that I followed.

    The grille is compromised of a chrome plastic piece mated to a base plastic piece via 30 or so tabs in slots. I figured out from looking that at the factory they stick the chrome piece tabs through the base piece slots and then hit the back side with a soldering iron to melt the end of the tab so it swages out, kinda like a rivet made of plastic.

    I used a dremel (probably the one tool I'd absolutely insist on having for this job) with a cutting wheel to cut the chrome ends of the tabs off on the backside of the grille. After all of them were cut off I carefully separated the chrome piece and the base plastic piece.

    Step 1 - Chrome Trim Removed.jpg
     
  2. Jun 12, 2009 at 8:21 AM
    #2
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Next I cut the grill section out with the dremel from the base plastic piece.

    Step 2 - Grille removed.jpg
     
  3. Jun 12, 2009 at 8:21 AM
    #3
    98tacoma27

    98tacoma27 :POOPCORN: Staff Member

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  4. Jun 12, 2009 at 8:23 AM
    #4
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Next I bought some expanded metal (16 gauge) from a steel yard and trimmed it to fit the opening.

    Step 3 - Expanded Metal cut out and trimmed to fit.jpg
     
  5. Jun 12, 2009 at 8:28 AM
    #5
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Next I overlaid the trimmed mesh on the back of the chrome piece and marked the openings at 6" intervals for studs to hold it in place.

    For studs I superglued and then JB Welded bolts in place at the previously marked locations. For good adhesion I recommend using the dremel cutting wheel to rough up the surface before sticking the bolts on.

    Step 4 - Bolts JB Welded in place.jpg
     
  6. Jun 12, 2009 at 8:29 AM
    #6
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Detail pic:

    JB Welded Bolts - Close Up.jpg
     
  7. Jun 12, 2009 at 8:39 AM
    #7
    Padilla1880

    Padilla1880 "Let's Ride!"

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    The suspense is killing, I wanna see this all finished!
     
  8. Jun 12, 2009 at 8:40 AM
    #8
    SaltySteve

    SaltySteve SMO

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  9. Jun 12, 2009 at 8:41 AM
    #9
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    After letting the studs (glued bolts) set up for 24 hours I put together the assembly with fender washers and nylon insert locknuts.

    Notice that I ended up trimming the bottom portion of the base plastic piece completely away. I also trimmed the expanded metal to only have openings at the attachment points (not required, but saves on weight and helps any possible clearance issues with the chrome and base plastic piece.

    I also did numerous trial and error fit checks during this step, trimming the base plastic piece to not interfere with the grille mesh. Be sure not to trim off the bottom two mounting points from the base plastic piece. They are where your grille snap mounts near your bumper and you'll need them.

    For reassembling the chrome piece to the base plastic piece I used the same factory method of tab in slot and then I hit the backside with a soldering iron. You may have to melt more of the plastic together since you cut the tabs shorter earlier, but it works all the same. I also slathered on JB weld at the top for added structural support.

    The mesh is painted with rustoleum satin black. If it doesn't hold up or I get bored I'll powdercoat it.

    The emblem that I got from my tailgate when I debadged is retained with 3 short pieces of allthread that I installed into bores that I drilled on the backside of it. I wet installed the allthread with superglue. I'm sure red threadlocker would work well also. It's held onto the mesh with locknuts.

    Step 5 - Assembly.jpg
     
  10. Jun 12, 2009 at 8:44 AM
    #10
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    While I was waiting for the studs / glue / JB Weld to set up, I masked off my front end and shot it with high temp black bbq grill paint.

    Step 6 - Black out behind grille.jpg
     
  11. Jun 12, 2009 at 8:45 AM
    #11
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Masking removed:

    Behind Grille Blacked out, masking removed.jpg
     
  12. Jun 12, 2009 at 8:46 AM
    #12
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Final Install:

    Step 7 - Final Assy.jpg
    Grille After 3.jpg
    Grille After.jpg
     
  13. Jun 12, 2009 at 8:48 AM
    #13
    Padilla1880

    Padilla1880 "Let's Ride!"

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    Great write up! Grille looks awesome!:headbang:
     
  14. Jun 12, 2009 at 8:51 AM
    #14
    phynyx38

    phynyx38 Believe

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    Awesome grill.
     
  15. Jun 12, 2009 at 8:54 AM
    #15
    SaltySteve

    SaltySteve SMO

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    Killer man. That looks sick! This isn't necessarily a Satoshi right so what's the mod name? It's gotta be something snazzy.
     
  16. Jun 12, 2009 at 8:57 AM
    #16
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Jamesoshi?

    Texoshi?
     
  17. Jun 12, 2009 at 8:59 AM
    #17
    Padilla1880

    Padilla1880 "Let's Ride!"

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    The Jamoshi sounds better!
     
  18. Jun 12, 2009 at 9:00 AM
    #18
    SaltySteve

    SaltySteve SMO

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    BAMF-yoshi?
     
  19. Jun 12, 2009 at 9:01 AM
    #19
    TX Tacoma

    TX Tacoma [OP] Fightin Texas Aggie

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    Jamoshi works for me. It's good to be immortalized.
     
  20. Jun 12, 2009 at 9:12 AM
    #20
    Padilla1880

    Padilla1880 "Let's Ride!"

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    How long did it take you to complete this?
     
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