SATOSHI MOD --- 1st gen. write-up (lots of pics)

I've attached a few pictures that could help a beginner body work person out. That seemed like it was going to be the most difficult part of this project because of the fiberglass work and such.

I'll start off with the fiberglassing since the obvious cutting is needed, we know that much. The best way to go about this is to get as close to level as possible, I understand why the 98-00 Tacos are difficult to do this with now.

Tape off both side on the inside of the grill:


Go over the top just a little, makes it easier in the long run:


Place the fiberglass inside the mixture, per directions and lay across the tape on the outside of the grill. (could not take pictures, play with fiberglass and you'll understand why) Once dried, remove the tape, yes it comes off easily:



I applied additional glassing to reinforce it, do so as necessary, I wanted a sturdy backing:



Now to the "Fun" part of it......Sanding.....
Get a block and sand with some rough stuff, you'll be doing it more than once so cutting it down is the key:



Before applying any Filler, clean the grill thoroughly to ensure proper adhesion. Soap and water or acetone will be fine.
I used the red putty stuff used in other Satoshi mods, you can use body filler, I just got this because I didn't need the entire can of Filler/Bondo. I have found through my experience that if you get the filler/Bondo can with hardener and such it will make it easier in the long run:

Keep going making sure to apply some pressure not only to cover everything, but to get into all the cracks.
Done with first round of filler:


Now sand everything with a block. I used some cardboard pieces with 600 grit wet/dry sandpaper. Using the block is critical to ensure you will be able to notice any holes or lumps anywhere, this will clear everything up.

Next, clean again with soapy water or a light layer or acetone; acetone will start to remove the putty, it is a strong chemical, you've been warned:

Now spray time! No you aren't done, this is to see where you messed up! :
I used this:

Light coats every 5-10 minutes should do the trick.
When done, you'll be able to see stuff like this:...Bummer...

and imperfections like this:

ewww you don't want that showing on your fancy new grill, do you?


I didn't take pictures here, but the process is simple...I call it rinse and repeat. Block sand the rough areas again down the fiberglass and fill the areas that need it. Sand that filler, clean and prime, once you can't see anything you are good to proceed to the next step.

I must have missed this, but I just sanded with 1000 grit wet/dry and used "Sealing Primer". Remember to clean before priming!

Now...template time.

 

To make your precious template keep in mind, you have one shot at this. Don't go crazy and try to just hack away at your metal and expect it to turn out perfectly.

Get a nice piece of cardboard, if you ordered your mesh from Homer, well...use his!
Make a rough draft:

I cut slits in the cardboard to guess how big I will really need to make it, this will help me at the end, measuring everything up.


I also made note of where all the tabs are since I want to utilize those to help secure the grill. Move your template to your mesh and trace:

Very good:


Start cutting, make yourself aware that you get one shot, keep fitting it to the grill to make sure you don't cut out too much. I just kept bending pieces back and marking where I could cut to:
Getting there:


Like I said, go slow....make many many cuts, this part takes time:


Pretty much there, just a few more cuts:


It's hard to tell, but I cut out two slots on each side to slide on to each piece since I will be riveting the grill in.


Tabs and all ready to go:


Just a little off center, I never said I was perfect But everything fitting nicely now:



Well, well, well...this actually is looking legit now:


I drilled some holes for my rivets, wiped it all down and painted it with engine enamel. I used an entire can and could still use a little more. Light, even coats every 10 minutes or so.
Riveted in:


Ready to go on; Satoshied!

 

^^ Looks great! You shoulda made your own write up though... especially for us guys with the 98-00 grilles

 

Well, I was going to, but I want there to be a like "master satoshi" thread....I'll do it I guess...

 

sweeeet. looks good

 

Here's a link to mine if you want to add

http://www.tacomaworld.com/forum/1st-gen-tacomas/202201-95-97-satoshi-build.html

 

Awesome thread. Subbed for when I do mine soon!

 

Just about finished with my 3rd 01-04 satoshi then will be doing a 98 if anyone would be interested send me a pm.

 

beautiful... wish i took it easy when i did mine 3 years ago.. mines looks like crap

 

thanks man. why not do it over?

 

the reason everyone is using bondo on parts of the grille is to smooth out the ends/cuts from where the old parts of the old grille insterts were right? so that they wouldn't show infront of the satoshi ?

 

fiberglass is drying right now on mine!

 

Perfect time to upload some progress pictures....

 

I'll have a few up in just a little bit! Got the bondo almost done today, one more touch up layer and final sand tomorrow then I get to shape my mesh. I'm not using any mesh like anyone else that I have seen though. I just picked it up from home depot and it doesn't look too bad it's mesh that's meant for cement work I think but different is good ? you'll see an example of it on the pic I upload of the triangle inserts that I finished doing tonight as well

 

EDITED. link to my pictures of my grille following this thread best I could
http://www.tacomaworld.com/forum/1st-gen-tacomas/263540-03tacomans-satoshi-grille.html#post6447735
Here's just a couple of pictures so far. Tomorrow I should have it finished 100% I think. Will make my own write-up of just how I did it pretty much the same but it won't be a bad thing to have my pictures up there as well
(you can see what kind of mesh i'm using in the picture of the triangles painted)

 

Thanks for the write up, it was helpful. One thing I did differently was instead of cutting out the 2 side grill inserts and then gluing them on, I used a small torch (pencil torch) to heat up each tab on backside then just pull off..then use the same tabs just put on heat tabs and smash em flat..worked great

 

well done good sir!

 

That looks friggen sweet! Digging the flat black hood stripe

 

Thanks..yeah I had the whole grill wrapped in it but it got damaged during the mod. Cheap way to cover the faded paint on my hood

 

damn im excited to do this again when i get my second taco. i miss her already...