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HOW TO: Mesh Grill - DNG's version

Discussion in '1st Gen. Tacomas (1995-2004)' started by DNG, Dec 12, 2011.

  1. Dec 12, 2011 at 8:46 PM
    #1
    DNG

    DNG [OP] Well-Known Member

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    Orange County, CA
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    White 01 DC PreRunner
    I've gotten a couple requests to write a "How To" for my version of a mesh grill, so here it goes.

    EDIT: If there are enough people who want these, I can make a couple for some price I haven't decided yet. PM me if interested.

    Materials:
    • Screen door mesh from Home Depot
    • Foam posterboard
    • Rustoleum High Heat spray paint
    • Cutting tool for grill assembly (dremel, hand saw, etc.)
    • Cutting tool for mesh (some kind of heavy duty scissors)
    • Rivet tool + rivets
    • Drill

    1. Cut out insides of grill assembly and file down until relatively flush
    [​IMG]

    [​IMG]

    2. Make a template out of foam posterboard to mold the mesh around. When making the foam template, I recommend making it a couple millimeters smaller, leaving a bit of tolerance between the foam template and grill assembly to allow for the mesh bends to fit inside. Foam posterboard seems to be the ideal material to use, as it is easy to file down to make precise adjustments
    [​IMG]

    [​IMG]

    I also recommend making as many cuts as you can around the corners to make them as round as possible (make adjustments as necessary)
    [​IMG]

    3. Insert molded mesh into grill assembly, drill holes, and install rivets. I recommend drilling for one rivet at a time, to allow for minor adjustments. No pictures, sorry.

    4. Spray paint radiator with Rustoleum High Heat spray paint.

    5. Enjoy :D

    [​IMG]

    [​IMG]
     
  2. Dec 12, 2011 at 9:52 PM
    #2
    Nitronick

    Nitronick Well-Known Member

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    Nick
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    looks awesome :)
    how much did it end up costing?
     
  3. Dec 12, 2011 at 10:52 PM
    #3
    IDtrucks

    IDtrucks Just out for a rip are ya bud?

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    96' X-Cab 4x4 TRD Off Road Clusterfuck
    JVC Deck, 10" sub mountd in rear seat cubby, 2 LED off road lights mounted in grille, amber raptor style grille lights, LED rock lights, square led bed light, custom made fuse block tray, 12 blade Blue Sea fuse block, 100a marine circuit breaker, black plasti dipped full grille, tinted tail lights + third, Uniden 520 with 4' firestik, Bilstein 5100s with 620lb Eibach coils, Diff drop, Chevy 63 leaf swap, TG creeper joints, 14" triangulated biletein 5125s, 8" extended steel braided brake line, TG Rock Sliders, CBI Moab 1.0 front bumper, custom fabbed bed rack, full TRD E-Locker axle swap and matching re-gear with custom stand alone wiring circuit, 29 spline pinion flange from an 06 wishbone runner, tubbed for 35x12.5" general grabbers on Ultra type 181 wheels, crush sleeve eliminator, Mini ARB compressor, front ARB locker, garage fab aluminum front skid plate, custom built high clearence rear bumper, removable mothafuckin doors
    looks great, i wanna do this to my 96


    the one step i want pictures for and nobody every puts up pictures.
     
  4. Dec 12, 2011 at 11:30 PM
    #4
    DNG

    DNG [OP] Well-Known Member

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    Orange County, CA
    Vehicle:
    White 01 DC PreRunner
    ~$60 for the grill
    ~$20(?) for the mesh
    ~$5 for the paint

    If I make another one, I'll be sure to snap pictures of that step.
     
  5. Dec 13, 2011 at 1:11 AM
    #5
    Blackdawg

    Blackdawg Dr. Frankenstein

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    Not that hard man. Im sure you can do it. Its pretty strait forward.

    Looks great man!!! I will be doing this soon as well :cool:
     
  6. Jan 8, 2012 at 5:57 PM
    #6
    Msilv25

    Msilv25 Member

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    1 1/2" lift 4300k HID's
    How did you make sure the grill curved with the rest of the front end? or did you just keep it flat?
     
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