custom metal work...welding and cutting...
 

I currently own a '97 4 runner...once i saw that there were limited options as to suspension and other accessories I decided to work on a jeep instead. I got some questions...I'm planning on cutting a piece of the grille on my truck out...what do i need to do...to do what's in the picture????
http://i75.photobucket.com/albums/i3...glergrille.jpg
you're probably wondering why I have a jeep grille in the picture?? the answer is because I'm planning to use it as my 4wheeler and honestly there are more options when it comes to suspension....
Well my plan is to only keep the outer shape of the grille(cutting out the mounts for the lights and the grille itself) then welding a new piece of sheet metal over the outer shape of the grille...
afterwards I will order a grill bib and all necessary parts to complete the FJ40 grille and try to weld that onto the sheet metal that is welded onto the wrangler grill...of course I'll need to make new mounts for the FJ lights...
from Rockymountaincruisers.com
http://www.rockymountaincruisers.com...79andnewer.gif
from Specter off road(sor.com)
http://www.sor.com/shared/image/112-401B.gif
http://www.sor.com/shared/image/112G2.gif
How do i start this project???

Not quite clear, you're going to take a jeep grill and make it into a FJ40 grill?

basically...yeah...i'm going to take the jeep grill...take out all the mounts for the lights...weld on a new piece of sheetmetal...then weld the fj40 grill....how do i start this project???

First thats some crazy cool shht you got going on. I guess you got welding skills? Sounds like to me if you're sure that this is the deal (like no doubt its going to fit back in) Start figuring your cuts. Measure twice. Then measure again. You dont wanna end up being a sad-sack.

so it sounds like a good idea??? also...what tools do i need to cut/saw metal off???

Yea it sounds like a cool idea, I dont know about a good idea but done right it would be unique. And I am all about unique. If you're feeling it then give it a shot. Do you have an air compressor? You'd need a pneumatic cutting tool. The thing with the little wheel on it. I would avoid any kind of saw.

ohhhhh...ok....i should probably get a rotary saw too right???

Just use a cutoff wheel on a grinder,but b carefull

consider a dremel for the tight cuts

ouuuu two more post for the small 3#

dang one more

when using a cut-off wheel,like anything, take into account the width of the wheel when making cuts...ive f'd that up a few times, heh.

Good choices would be a cutoff wheel mounted to a die grinder (air compressor needed), or a 4 1/2" grinder with a thin kerf cutoff wheel. You can always break out a reciprocating saw (Sawzall), but buy the right blade for cutting thin gauge sheet metal.
You can always make your cuts a little "fat", then grind down the metal to the desired opening width. It just depends on what tools you have, or have access to - like a buddies tools or shop.
Good luck

Check out this link. This guy put round headlights on a Cherokee.
http://www.colorado4x4.org/vbb/showthread.php?t=74113