I have not bothered to read this whole thread but ive got a good question from someone who made his own grille (wasnt ghetto, tons of measurements and drawing into cad.)
problem i had with making a grille for the solara was the mesh insert itself. I was never comfortable with it cuz if you insert a flat perforated mesh screen and roll it to the varying radi' of the grille itself (in both directions ,verticle and horizontal)
you still lack the "3d" affect most all grilles have(billit for example). Look around at any gen 1 "homemade" grille and you will see what i mean. you have a nice rounded frame and a flat insert..
i am wondering if any mesh has been installed and what it looks like?
Not knocking all the work done here just calling some attention to issues i had
Only way i got a mesh insert to look right was to apply it directly over the stock "slots". this gave the correct "stock" 3d look. and since this was my only success in shaping the insert i gave up
