Installing your Roadless Gear SJ410 Grille
Kit
This kit is designed to change the style of your stock Samurai grille
to the older, SJ410 style. You achieve this by cutting the center
section out of your stock grille and then screwing the new SJ410 section
included in this kit into its place. The new grille can be painted
to match the rest of your grille.
Step 1 – Remove your stock grille from the vehicle
This is a no brainier, 5 Phillips screws in the center section, one
in each corner and one at the top middle. There are 2 pins on each
side of the grille at the outsides of the headlights. They just are
pushed into matching holds to hold the edges of the grille in place.
Gently pry these pins out and the grille will pop out into your hands.
Step
2 – Cut the center section of your stock grille.
You can cut the plastic of your stock grille with a jigsaw, if you
use this tool go very slowly so the vibrations do not start snapping
the plastic. You want a clean cut, not a break.
We have found the best tool for this job really is just
a hot knife. We take an old utility knife blade, grab it tight with
a pair of vice grips, then heat it over a torch and get it good and
hot. It will then slice through the plastic like butter. When it starts
to get harder to cut, just heat the blade up again and continue. Be
sure you are in a well-ventilated area (melted plastic gives off toxic
fumes). Also, we shouldn’t have to tell you to make sure there
are no flammable substances nearby (but our lawyer insists we tell
you anyway).
When
cutting, error on the safe side. Make your first cuts a little longer
than they need to be. If you screw up, you can always go back and
remove some more material, you can’t go back and add material.
Be sure you do not remove the tabs for the screw holes that mount
your grille to the vehicle. Cut around these, leaving them attached
to the outside of the frame. You need these to mount your grille back
on the vehicle.
When you are all done cutting, finish the inside of
the opening with a sander to smooth out the burrs and high spots from
your cut. You should also run a sander down the forward facing edges
along the sides. The stock grille has “high spots” from
the bars you removed that should be sanded flush so you get a flush
fit of the new center section.
Step
3 – Mount your new SJ410 center section
Your new SJ410 center section comes pre-drilled with mounting holes
for the screws that will hold it in place. Line it up straight over
the (now empty) stock grille center section. Temporarily hold it in
place with some masking tape and then drill 0.116” holes into
your stock grille through the matching mounting holes. Now just use
the included screws to attach your new center section to your grille.
Do not be tempted to use a screw gun to drive the screws in. This
is very thin plastic we are dealing with. Don’t be in a hurry
– use a screwdriver and go slow.
That’s all there is to it. Just paint it any color
you wish and reinstall it in your vehicle in the reverse order in
which you took it off.
Order yours today by clicking
here!
