Ted,
My Suburban doors, hood, fenders, and grill were all painted off the truck (grill in pieces). We put it all together without any scratches/chipping.
If you are going to paint the grill to look original, I think it would have to be painted in pieces, in order to paint the inner bars another color. I have put two grills painted in parts back together with no scratching/chipping.
Pre-fit the grill and all parts before painting in pieces off the vehicle.
Of course, the running boards, bumpers, and seat frames were also separately painted (off the truck).
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Cab painting sequence that we used:
Bottom of the cab painted black.
Firewall painted exterior color
2 mil poly sheet placed over the frame/engine and the entire chassis.
Then put the cab/body on the chassis (on top of poly sheet)
Interior cab was painted first, then the inner cab was masked off at the door seams and the exterior color was applied.
Separately-painted parts then installed.
Tim
