My Tacoshi Grill
I purchased the expanded steel from a local weld shop and fabricator here in Phoenix.
First step after removing the grill, use a small coping saw or Dremel and remove the center ribs.
After removal you will have two notched out sections on each side.
From this cutout section is were you will salvage pieces for filling the cut out
a.) Take a piece of study cardboard and place it behind the notches and trace out a template to use
for tracing out your pieces to cut from your cutout pieces from the factory grill center.
b.) trace onto the salvage plastic, the pieces to cutout.
Note: take your time. The more precise the cuts the easier it is to put in place for gluing. This is where the true craftsman comes into play. You only have a couple of flat pieces to work with so be careful.
Your pieces should look something like this. Or close too.
This glue is incredible strong and sets up pretty fast. I recommend letting it set up overnight.
When it is dry it sets up like fiber glass without all the mess. Just don't get to crazy with it
you have to sand all the excess off and, like I said, it is like a rock when it sets.
After setting up, time to sand.
After the first round of sanding, I applied body filler to the holes and any gaps.
Then round 2 of sanding.
a.) Next, I trimmed my steel to around to 1" overlap of the grill hole cut out and trimmed it to shape.
- To get my shape I flipped over the grill font side down and laid my steel on the cutout and positioned it so that the pattern was level [horizontally] and with a SHARPIE, drew out my pattern.
My expanded steel was stiff and study but I was able to complete my cuts with tin snips.
Once again, take time and draw out your cuts and don't rush.
b.) I then primed it with 3 coats of primer.
c.) Then painted it with 4 coats of Morton's Truck and Bed.
Sprays on thick and has a textured look and finish.
Placed 12 screws around the outside of the grill and glued them down with the glue that I used
to glue my cutouts in place.
Note: I filed down one side of the screws so they laid flat against the grill so that they ran straight with the grill and not at a angle.
Bolted down and sprayed the back side with the Morton's [not shown]
... done. Took a emblem off the ass end, trimmed it and bam!
Just a couple notes: Don't rush this. If you want it to turn out right, take your time. My job took 4 days.
This isn't a day project and some give the impression it is.
Secondly, do it right. I have seen grill made with flimsy grating for airducts and all crazy shit. USE high quality EXPANDED STEEL. Just don't get it too thick. REMEMBER, YOU HAVE TO CUT IT!
Lastly, take care to mount it properly. I have seen folks mount the grill with zip ties WTF! You created this work of art why would you go on the cheap!?
My grill with stand up to punishment. It will the car wash, machine, hand pressure. But I went the extra mile.
Take your time. You are customizing.
My Taco build