BPF 2007-2009 Toyota Tundra Mesh Installation Guide www.bpfabricating.com Tools Required Philips Screw Driver Flat Head Screw Driver Dremel or Rotary Tool Hand Saw or Multi Max Adjustable Square Tape Measure Marker Zip Ties Drill 1/4 inch Drill Bit 1/8 Drill Bit Sandpaper or Sander ABS glue Yellow Plastic Welder or Solder Gun (Bondo will work as well) Black Paint (a textured paint will hide any blemishes) Masking tape 2+ Clamps It is a good idea to take your time and read the installation guide thoroughly before starting. Please ask us about any questions you have about the installation process, we are happy to assist you! Need help? Questions? Please, contact us at bpfabricating@gmail.com 1. Start by removing the hood latch bracket on the back of the grill. A Philips Screw Driver will be needed. Next, lay over the new hood latch bracket. Using masking tape lay it over both sides of the hood latch bracket on the OEM metal bar.
2. You can now remove the OEM bar leaving the masking tape on. Set the new hood latch bracket on top of OEM bar. Using a marker, mark out the holes. You can now drill out the mounting holes (using a punch will make things easier). 3. It is also a good time to drill out the mounting holes for the mesh. Drill out the holes like the photo below. They do not need an exact location, just close to the photo will work. About 6 inches apart. 4. We are almost done with the OEM bar. Lastly we need to slit a notch the ouster inside ends to allow for a little more clearance for the mesh. You can use a grinder or a Dremel tool for this. 5. You are now finished modifying the bar. It is a good idea to paint the bar so there is no bare metal showing. 6. Next using a flat head screw driver separate the inner and outer grill shrouds.
7. Cut out the center of the grill. Use a hand saw or a Multi Max or a Dremel. It is okay to leave some material on as you can clean up the edges after. 8. This is probably the most changing part of the install. With some patience and a steady hand, you can do it! Trim down the grill so that it will sit evenly. Before trimming, you need to draw on some measurements to adjust the grill depth. We recommend to measure twice on the areas that are cut. Make sure the grill is face down. All measurements will be taken on the inside perimeter of the grill. Measure all starting points at the inside of the front face (furthest point from you), towards the inside back end point (closer to you). At each point that requires measurement, make a mark with a marker/pen on the INSIDE of the grill. See the diagram below on the areas to measure. top 1 3/4 inch *Face Down 3/4 inch 3/4 inch Measure towards you. Inner backside of grill Inner finished front (Measuring starting point) bottom DRIVERS SIDE 1 7/8 inch PASSENGERS SIDE
Double check your work. It is very important to verify that all marks are accurate before the cutting process. Once all marks are correct you can use a ruler/meter stick to connect some of the marks 9. Using masking tape give yourself an edge to cut alongside as a guide. It may help to clean up the edges. Flow the edge of the cut line and use it to connect all the marks drawn. Take a step back and make sure everything looks correct and that you will have a flat edge. Now is the time to make any changes. 10. Using a Dremel with a cut off wheel, cut the edges of the grill following the masking tape line you made. 11. You are almost done. Now you need to fill those gaps on the sides using the material you cut off. Trim it so that it will sit flat or flush with the back of the grill. Once trimmed use the ABS cement and clamp in place. Work your way around the grill till all six gaps are filled. 12. Once dry you can use Bondo to fill in the rest of the gaps. Or you can plastic weld using a soldering gun by adding more plastic and melting the pieces together. Shown below is the plastic weld method.
13. Sand the insides of the grill and clean up the edges. Now is a good time to test fit the mesh and make sure it sits flat. If not, sand it down till it does. Once smooth you can get it ready to paint. 14. You can clean the grill with rubbing alcohol and paint it. We like to use a lightly textured paint. 15. Attach the new hood latch bracket to the OEM bar, using the supplied hardware. Attach the old hood latch bracket to the new one. 16. Put zap straps through the holes you drilled in the OEM bar. As its difficult ones it s installed. 17. Put the inner and outer grills shrouds together and reinstall the OEM bar. 18. Place the grill mesh on the back side of the grill. It is a tight fit with close tolerances so take the time to make sure it lines up correctly. Next you can zap strap the mesh down to the grill. Before tightening the zap straps make sure the grill is still lines up. 19. If you ordered lettering now is the time to install it using 3M doubles sided tape. Congratulations, your grill is now complete! Be sure to send us a photo of your work, we would love to share your photo. Direct message or Tag us on Instagram @bpfabricating or email it to us at bpfabricating.com. Thank You!