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Satoshi GrillCraft *How To* w/ pics

Discussion in '2nd Gen. Tacomas (2005-2015)' started by Klipp11, Feb 18, 2010.

  1. Feb 18, 2010 at 3:17 PM
    #1
    Klipp11

    Klipp11 [OP] s3

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    decided to install a grillcraft on my tacoma so i can mount some hellas behind the grill down the road

    after considering the fiberglass / bondo method, i decided on another route. i fabricated a piece of oem plastic from the crossmember to fit perfectly in the gap left from the cut, then used an epoxy resin to set it in. very strong...

    check it out:

    oem grill
    [​IMG]
    remove the grill by removing the two plastic flare clips using a flathead screwdriver
    [​IMG]
    and 2 bolts with a socket
    [​IMG]
    then lift the grill straight up to release the two clips holding the bottom of the grill
    [​IMG]
    tested the grillcraft by placing it on top; fits good
    [​IMG]
    next cut the 2 crossmembers out of the center of the grill (use a reciprocating saw or dremel with a cutting wheel)
    [​IMG]
    if you want to mount the gc flush, you're already done at this point. (just drill a couple holes and fasten the gc to the grill using the hardware that comes with the kit)
    [​IMG]
    personally, i wasn't thrilled by how it looked on my truck and wanted to see how it looked satoshi'd...
    cut the crossmembers in half and dissect the only two pieces of flat plastic from them like this
    [​IMG]
    to yield this
    [​IMG]
    trace a template of the piece you want to make using a sharpie and some cardboard
    [​IMG]
    then cut your template from the cardboard with scissors and trace it on the plastic. then use a cutting wheel to carve it out
    [​IMG]
    fine tune your insert until it fits nice
    [​IMG]
    [​IMG]
    when you're satisfied with the fit, epoxy it from the back (make sure you sand down the edges of the bonded surfaces so the epoxy has somewhere to go and cement the two together), let dry for 15 minutes, then sand it down so it looks like this
    [​IMG]
    then apply a coat of finishing putty
    [​IMG]
    and sand with 320 grit until smooth and the edges of the putty blend in smoothly to the plastic, then use 400 grit to finish it off
    [​IMG]
    tape it up
    [​IMG]
    and paint it (i used flat black trim spray paint). use 2-3 thin coats, letting it dry thoroughly between coats
    [​IMG]
    remove the tape, drill a couple holes to fasten the gc to the back of the grill, and you got yourself a damn nice grill!! :D:thumbsup:
    [​IMG]
     
    Bravisimo likes this.
  2. Feb 18, 2010 at 3:23 PM
    #2
    ekard

    ekard Well-Known Member

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    Wow, that seems a lot simpler than the fiberglass/bondo approach. Nice thinking!

    Let us know how it holds up over time.
     
  3. Feb 18, 2010 at 3:25 PM
    #3
    jacob_wood

    jacob_wood Screw your MPG's

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    Great thinking and very nice write-up +rep for you!
     
  4. Feb 18, 2010 at 3:27 PM
    #4
    Tim A

    Tim A Well-Known Member

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    Very good idea
     
  5. Feb 18, 2010 at 3:28 PM
    #5
    Klipp11

    Klipp11 [OP] s3

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    dude, this epoxy is the shit. after setting for 5 minutes, i could hold up the entire grill surround by the piece i bonded to it. also used it on my fender flares when i trimmed to fit the 305's. it's a two part resin that mixes together in the nozzle when applying and cures in under a minute
    [​IMG]
     
    Bravisimo likes this.
  6. Feb 18, 2010 at 3:37 PM
    #6
    TJ Asher

    TJ Asher Well-Known Member

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    Great write up and pics. Makes a complicated mod look simple.

    +1 rep for you!
     
  7. Feb 18, 2010 at 3:38 PM
    #7
    1BlkT

    1BlkT Mod'n on a Budget

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    Nice looking grille! Your steps were similar to HBMurphy, I think the difference is he used ABS glue to bond the two plastics.

    Do you think there will be any problems with the plastic flexing a little causing the paint to crack and show the seam? I might have to try this method because I personally am sick of the fiberglass mess.
     
  8. Feb 18, 2010 at 3:39 PM
    #8
    Capita

    Capita Well-Known Member

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    great write-up and pics. Looks really good
     
  9. Feb 18, 2010 at 3:42 PM
    #9
    Slimwood Shady

    Slimwood Shady I love your mom!

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    Nice write up! I am not so nervis to do this mod now!
     
  10. Feb 18, 2010 at 3:44 PM
    #10
    08TRD Sport

    08TRD Sport ROOTIN AROUND

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    thanks for the easy way!!!!
     
  11. Feb 18, 2010 at 3:45 PM
    #11
    Klipp11

    Klipp11 [OP] s3

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    i can't see it cracking. that's why you just mist the paint on over a couple of layers. and the epoxy is so solid that it won't allow any movement anyway
     
  12. Feb 18, 2010 at 3:46 PM
    #12
    Slimwood Shady

    Slimwood Shady I love your mom!

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    Can you post a close up pic of how you mounted the grill craft to the grill?
     
  13. Feb 18, 2010 at 3:51 PM
    #13
    blackhawke88

    blackhawke88 wo ai ni bao bei ^_^

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    awesome job! :thumbsup:
     
  14. Feb 18, 2010 at 3:52 PM
    #14
    Klipp11

    Klipp11 [OP] s3

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    yeah sure. i'll take a pic for you tomorrow and post :)
     
  15. Feb 18, 2010 at 3:53 PM
    #15
    Klipp11

    Klipp11 [OP] s3

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    thanks aaron, that means a lot coming from mr. satoshi himself!! :D
     
  16. Feb 18, 2010 at 3:53 PM
    #16
    Chris(NJ)

    Chris(NJ) Well-Known Member

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    2nd! Post up some more pics... installed too :D
     
  17. Feb 18, 2010 at 3:56 PM
    #17
    neslerrah

    neslerrah Taco lovin'

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    Great job, looks great. :thumbsup:
     
  18. Feb 18, 2010 at 4:03 PM
    #18
    thestrangebrew

    thestrangebrew AlphaPlanner

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    subscribed. looks awesome!
     
  19. Feb 18, 2010 at 4:04 PM
    #19
    Simon2150

    Simon2150 Well-Known Member

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    +1 for you. Satoshi mods seems easier doing it that way!
     
  20. Feb 18, 2010 at 4:07 PM
    #20
    08TRD Sport

    08TRD Sport ROOTIN AROUND

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    needs to be made a sticky
     
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