View Full Version : My 2000 4runner build, repair, and modification thread

Stick Figure
01-03-2012, 03:27 AM
Since I am starting to post over here a bit more I figured I would post my pics and mods as well.

Picked up my truck in august of 08 (pictured with my other vehicle at the time)

It was basically stock minus the running boards with around 123k on it. It was exactly what I was looking for 2000 "Highlander" edition so it had the scoop, the locker, and no multi-mode 4x4 system. I think at the time I said something about probably not seeing any off road time, lift etc.

First "mod" (Dec of 08) was to get rid of the pseudo water pump that Toyota used on the 5VZ-FE to run the clutch fan. The bearings in the idler puller were making noise, and Toyota wanted a lot of money for it, and the auto parts store version didn't look like good enough quality to even be an option.

I made a fan shroud for a couple of perma cool fans I had laying around.

cut the end off of the idler and re-routed the belts

I installed a fan switch from a Honda (yeah i know but again it was laying around)

Around the same time I also did an alarm/remote start and a new deck, but I don't have photos of that ... so moving on...

Jamie (g/f) and I decided to take a long weekend over Memorial day (09) and go explore the AZ strip.

Truck was great over the trip other than breaking a belt in on the cheap Remington tires that were on it when I bought it. We drove back on the spare, and I searched around on craigslist for a solution and found a deal on some 4th Gen 4runner wheels and BFG all terrain tires.

only "problem" was that they were an inch taller than stock

the "good news" was that the stock suspension got pretty abused on the strip anyway, so i figured a mild upgrade was in order. The 99 Highlander 4runner was available with taller springs than any other year 4runner so that is what i picked up along with some Bilstein heavy duty shocks.

much better!


and it got me playing around off road even more....


and more coming up ...

Stick Figure
01-03-2012, 03:55 AM
Did a few trails in that trim


more pics:

made some on road trips x-mas etc nothing too fun
March of 2010 we drove from southern cal to a town (name escapes me) just east of Salt Lake City to pick up some FJ Cruiser wheels. The 4th gen 4Runner wheels never did have a great offset for the 3rd gen and I didn't want to run spacers. Oh and yes that is a ridiculous trip when we could have shipped the wheels or bought them locally to us, but it was a good get away, and I got new truck parts so I don't see how you can go wrong!

more concrete trips hauling some of my crap back from Nebraksa

Thanksgiving 2010 we were playing around off road and I snapped another front end link. I decided to make myself a new set,
so I tried a quick disconnect design.

Next mods came in Dec setting the 4runner up for another Towing trip from Nebraska.

First was OME 890's in the rear
Super raked? yep .. for a reason

I also wanted some better lighting. I had previously swapped the headlights to HID's and lost the high beams, so I picked up some PIAA's and wired them to the stock high beam switch.

Last mods at that time was a Pioneer AVH P4200 dvd screen and some husky liners for the front.

now the reason for rake? I had to tow this thing back

.. bit more coming up

Stick Figure
01-03-2012, 04:10 AM
While fixing the leaking valve cover gaskets, I decided to make some teflon gaskets for the throttle body and intake manifold.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FIntake+Gaske ts&i=IMAG1594.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FIntake+Gaske ts&i=IMAG1612.jpg&s=1000

why teflon? they block the transfer of a heat, and are pretty much indestructible. They did drop manifold temp a little bit which did gain a small amount of MPG/HP. would I pay a lot of money for this mod? NOPE... Would I grab the scrap material (from other gasket making) and do a set again? yep in a heart beat.

It took a while but the rake had finally gotten to me by May of 2011, and something had to be done...

Started with boring some holes in a couple pieces of scrap

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3135.jpg&s=1000

Then rounded them out on the mill at work

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3169.jpg&s=1000

I wasn't sure on an exact size at this point since i hadn't pulled the strut out of the 4runner yet. Back at home i pulled the struts and actually measured them. Time to reduce the size .....

First one was done entirely on my benchtop lathe

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3170.jpg&s=1000

After i had the exact size i wanted

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3172.jpg&s=1000

it was easier to to trace the rough size measurements to the second piece and trim it on the band saw

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3174.jpg&s=1000

almost done ....

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3175.jpg&s=1000

little time in the drill press and

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3180.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FFront+Top+St rut+Spacer&i=IMAG3177.jpg&s=1000

After installation and alignment:

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=trips-car-shows-offroad-adventures-and-other-misc%2FDelamar+Mt+trail+and+Gold+Mountain+truck+tr ail&i=IMAG3217.jpg&s=1000

Stick Figure
01-03-2012, 04:23 AM
At this point the truck had around 180k on it, I knew the rear axle seals were leaking (and had been), the front end was feeling a little sloppy, and the tire wear wasn't that great. Up until this point I had only replaced one inner tie rod and the steering rack bushings. I figured it was time for everything else...

So overall I replaced:

Wheel bearings front and rear
All associated seals front and rear
Upper and lower ball joints front
outer tie rod left and right
inner tie rod left (right was replaced around a year ago)
Steering rack internal guide bushing, springs and lock

I picked up a small 12 ton press from Harbor Freight to do the work. I figured for $100 (sale price) if it meant i didn't have to run the parts to work, or bother my neighbor it would be more than worth it.

I did make my own SST for the rear bearing removal. Using this and a bearing splitter, i also managed to remove the ABS exciter ring with out cutting as per the factory service manual. I still replaced the retaining ring even though it wasn't technically damaged during removal.

The front bearings did take some pressure. This has been a CA vehicle its whole life, and has pretty much zero rust, but it still took every ounce of pressure that little 12 ton could muster. In other words if you have a vehicle from the rust belt, the 12 ton probably won't do it!

Truck drives soo much better now, its unbelievable ... i still have a slight bit of shake, but i'm guessing that is going to be mostly tire related at this point.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0024.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0127.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0134.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0135.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0152.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0205.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0214.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0231.jpg&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2F180k+Suspens ion+tune+up&i=IMAG0209.jpg&s=1000

and then hopped in for a trip up to Florence Oregon...

It wasn't a pleasure trip so no wheeling pics on this trip either. :(

Stick Figure
01-03-2012, 04:36 AM
Now that the truck was back to what I would call good running and driving condition it was time for some more actual upgrades. I wanted to get the Jack and shovel out from inside the vehicle and made up some brackets to mount them on the stock roof rack.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FRoof+Rack+Br ackets&i=DSC05677.JPG&s=1000

The only problem with them is that the "shovel" I had for the truck was nice and petite so it would fit in the back with no problem.

Now that its on the top it looks....... well cute ....

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FRoof+Rack+Br ackets&i=DSC05682.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FRoof+Rack+Br ackets&i=DSC05686.JPG&s=1000

The other plus side to this is that I think I could actually do a double bracket to fit an axe and shovel combo on one side. I've never needed an axe, but it never hurts to be able to carry more gear for certain trips.

Final pic of the jack mounted on the other side of the truck.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2FRoof+Rack+Br ackets&i=DSC05689.JPG&s=1000

No I don't believe in quick wing nut mounts. I carry enough tools that removing a couple nuts to gain access isn't a problem, and I liked the added security.

Next mod was this!

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC05705.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC05708.JPG&s=1000

I know my intake is awesome lol .... actually its just a temporary setup but it serves a purpose.... I needed more room

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC05709.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC05710.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC05713.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC05719+%281%29.JPG&s=1000

Battery tray isn't quite done yet, but figured I would share the progress pics. I still have to make a bracket for the cruise control, and actually do some testing on the intake and finalize a design.

This was about where I decided to accept the job offer up in San Jose and had to finish things up to be prepared for moving all of my crap. So some of this stuff is still in a temporary state.

First up was to get rid of the less than perfect BFG's (worn suspension sucks) and switch to some Falken Wild Peaks/Rocky Mountains. My only complaint with these tires is that in my 265/70/17 Size I had two options a half tread 2 ply side wall version or a full tread version but with 10 ply sidewalls. I would have liked to stay with a 3 ply sidewall like the BFG's but wasn't paying that price again for those.



Overall I was pretty impressed with the new tires... they are just a bit rough at higher speeds on crappy freeways etc.

Stick Figure
01-03-2012, 04:49 AM
Since I wanted to make things functional before the move, I need to get things wired..

The idea was to use the second battery to power some future accessories, so the first step was to run some 4 gauge wire from the battery to the back of the truck.

At the back I ran it into a 4 way split, and then into a fuse box.

I found this Dorman 4 fuse box for like $5 and figured it would work good. My only issue was that the power inlet side was connected, and my crimpers would not fit, so the wiring had to be soldered only.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07847.JPG&s=1000

On the plus side it allowed a very nice look, and you could probably get by with only one or two wires on the source side.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07848.JPG&s=1000

The outlet side were individual terminals, so I was able to do a proper crimp before soldering.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07850.JPG&s=1000

4 gauge was finished off in my traditional way ... tin the lead, and round it

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07852.JPG&s=1000

Couple shots of how the back turned out and the positioning of everything.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07855.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07856.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07858.JPG&s=1000

From there one output wire is heading to the stock "cig lighter" plug, one is for the box that's in the mail, and I did one more that is for future use if needed.

I wasn't happy about not having easy access to the fuse panel, but I couldn't figure out an easy way to make that happen. I think in the future an access hole will be cut.

I wanted to add another power plug to the back of the center console, and originally thought about using the 4th output of the fuse block to run back up front. I decided that wouldn't be much better than the factory wiring after making that long of a run.

I decided to split the wire in the kick panel to have additional power capabilities up front. First step was to find another splitter. Once I found one, I had to make a bracket to hold it in place....

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07859.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07860.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07861.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07862.JPG&s=1000

Next step was to install....

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07864.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07865.JPG&s=1000

you will notice the fuse holder where I tapped power for the front aux power port.

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07869.JPG&s=1000

From there I moved under the hood to install a main fuse. The location I wanted to use was occupied by a bracket for some relays. I started by fabbing a bracket for my circuit breaker.

Pictured next to factory relay bracket
http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07870.JPG&s=1000

a little more cutting, welding, and painting later ...
http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07872.JPG&s=1000

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07874.JPG&s=1000

and installed:

http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07882.JPG&s=1000

Final pic for today is a preview of how I am charging the second battery
http://www.mostdesigns.com/zgallery/zp-core/i.php?a=Personal+Vehicles%2F4Runner%2Fadditional+b attery&i=DSC07879.JPG&s=1000

(no that solenoid didn't end up working and has since been replaced with a proper one)

and for the final upgrade before my move ...



... a Whynter 65 Qt. Fridge/Freezer.

For wiring I used one channel of the previously installed fuse block to power the fridge via “banana clip” style plugs. I wanted something a little more secure than a standard cigarette lighter plug that seems to vibrate loose on every trail we’ve ever been on. Rather than sacrifice the original power cord, I found a match from an old laptop PC, and converted it to the banana clip plugs now needed. This way the fridge can still be plugged in to the front auxiliary plug ins if needed.

That pretty much brings us up to date minus a few minor things here and there. Currently I'm not able to upgrades since I'm looking for some shop space and a new place to live in San Jose. Its taking a bit longer than expected because of my "brilliant idea". When I saw the average cost of a rental house here and lack of a 3 car garage, I decided it would be better to rent aprox 1000sq ft industrial space for my projects, and tools, and just live in a small apartment for everyday life. Well its been harder here than anywhere else to give my money away.

Luckily the 4Runner has been a champ towing cars, and trailers and basically living out of it with out having a bigger issue than a tail light bulb burning out.

Questions and comments are more than welcome ... Right now I have more time to answer them than I will when we start moving everything out of storage!

01-03-2012, 05:11 AM
gorgeous fab work

01-03-2012, 05:24 AM
gorgeous fab work


All the mods look factory original!

Stick Figure
01-03-2012, 01:26 PM
Thanks for the compliments guys. I just can't wait until I can find some time to do more stuff. I'm thinking possibly a drawer set up or at least a new tie down system in the rear.

01-05-2012, 02:23 AM
Very good work, it all looks well done.

Stick Figure
01-05-2012, 04:53 AM

trying to figure out what to get it for its 200k mile b-day .. the recent move has pushed it up 193k and it deserves something after towing all those damn trailers.

01-26-2012, 09:18 AM
Time to get your Ham radio license and get yourself a nice radio for communication :). Ive been hours from any town or cell service but can always reach a radio repeater.

01-27-2012, 08:04 AM

trying to figure out what to get it for its 200k mile b-day .. the recent move has pushed it up 193k and it deserves something after towing all those damn trailers.


For every "birthday" of my truck, I have taken it on a trip. 40K was my best friends bachelor party camping trip... 50K was the White Rim Trail in Moab. I was @ 60K on Elephant Hill in Canyonlands. 66,666 hit just as we finished Fin's N Things. 70K was when I took my girlfriend (now wife) camping near Dutchman's Draw (AZ strip?), which was the first time I've ever had a sidewall puncture.

I have a big trip planned for 80K, which is in about 2500 miles. :D

I'd take it to Moab, buy the CHARLES WELLS GUIDE TO MOAB (http://www.amazon.com/Guide-Backroads-4-Wheel-Drive-Trails/dp/1934838004/ref=sr_1_2?ie=UTF8&qid=1327654941&sr=8-2) book and go nuts. I'd recommend something like the White Rim for a 200K milestone. :)

01-27-2012, 02:52 PM
Good build! I would think the though the dual battery set up would block airflow to the filter, i'm sure its negligible though.
Have you thought about upgrading the front brakes to tacoma size?

01-29-2012, 02:05 PM
Good looking truck. I like the fabrication you have done! I wish I still had access to a shop for fabrication.

How much space is between your radiator and the fan shroud?

Have you thought about adding some sort of door to allow you access to your fuse blocks? That way in the event a fuse blows, you can get access to it without pulling the panels out. I have my accessory fuse block in the driver's kick panel and have been thinking of ways to place a door over the area to gain access.

Stick Figure
01-30-2012, 03:04 AM
Time to get your Ham radio license and get yourself a nice radio for communication :). Ive been hours from any town or cell service but can always reach a radio repeater.

A radio is something I haven't thought about much, but know I should. Most of the adventures we have done have been in southern cal where even on a hike I was answered craigslist texts, and tweeting pics of our hike. We were never more than maybe an hours walk from phone reception at the most.


For every "birthday" of my truck, I have taken it on a trip. 40K was my best friends bachelor party camping trip... 50K was the White Rim Trail in Moab. I was @ 60K on Elephant Hill in Canyonlands. 66,666 hit just as we finished Fin's N Things. 70K was when I took my girlfriend (now wife) camping near Dutchman's Draw (AZ strip?), which was the first time I've ever had a sidewall puncture.

I have a big trip planned for 80K, which is in about 2500 miles. :D

I'd take it to Moab, buy the CHARLES WELLS GUIDE TO MOAB (http://www.amazon.com/Guide-Backroads-4-Wheel-Drive-Trails/dp/1934838004/ref=sr_1_2?ie=UTF8&qid=1327654941&sr=8-2) book and go nuts. I'd recommend something like the White Rim for a 200K milestone. :)

Some trips are in the future, but just moving up to the bay area from southern cal, we are still recovering financially, and can't really ask new jobs for a ton of time off, so they will just be some weekend fun for now.

Good build! I would think the though the dual battery set up would block airflow to the filter, i'm sure its negligible though.
Have you thought about upgrading the front brakes to tacoma size?

Filter is being blocked a bit, but the bigger problem would be the shorter tube affecting the tune a bit. Seems to have moved the power band up higher than I would like for a truck application. I had planned to redo the intake and build an actual box again, but the above mentioned move has pushed this back a bit.

For brakes are you thinking of the Tunda upgrade, or did I miss something about the Tacoma having better brakes too? I do have the larger factory brakes, and don't find them as bad as some people seem to think they are, but as I add more weight, bigger brakes can never be a bad thing. I've been doing a bit of looking at changing the rear drums to disk, but want to keep it all Toyota including keeping a rear drum e-brake with the disk brake conversion. We'll see if it happens or if I just freshen up the stock system that has never let me down.

Good looking truck. I like the fabrication you have done! I wish I still had access to a shop for fabrication.

How much space is between your radiator and the fan shroud?

Have you thought about adding some sort of door to allow you access to your fuse blocks? That way in the event a fuse blows, you can get access to it without pulling the panels out. I have my accessory fuse block in the driver's kick panel and have been thinking of ways to place a door over the area to gain access.

I believe It's about an 3/4" or so. Its been a while since I did that and don't recall right off.

I really wanted to add an access point when I did the original install, but didn't have anything laying around the garage that would work. I am open to suggestions of ways to do it, and have it look factory. None of the panels I had laying around off of other cars had anything that would work to retro fit. I would like something like a port hole style where I could cover up my cut and not have to try to be TOO careful. lol

Thanks for the comments guys. The truck did get a bit of a early b-day present by way of a new die hard platinum battery to replace the Panasonic. I do like the Panasonic's a lot but the abut it had seen before the install was just too much for it and it wasn't keeping up with the fridge anymore. I wussed out and stuck with the group 35 battery size. In reality I was just too lazy to re-wire for the reversed terminal arrangement that the other platinum options offered. I'm going to use the excuse that at least now it matches the stock size and config so it can be moved over to starting duty if ever needed though.

01-30-2012, 12:36 PM
Yeah i meant tundra. :/ I'm looking upgrade the brakes on mine next, especially since the front OEM rotors decided to warp.

02-03-2012, 04:56 PM
Any plans to make those gaskets? I would love to get my hands on some. Did you cnc them or cut them by hand?

Stick Figure
02-08-2012, 04:55 AM
no cnc capability for me just yet lol, those are done by hand. I will have my new workshop up and running soon, and can pretty much make anything that i have made for my own truck, but I'm still a couple weeks off of being able to work in it.

02-08-2012, 03:33 PM
Great work! I have read your thread through a couple of times - the fit and finish looks amazing. How thick are the front spacers that you made? How much lift did you get out of them?

Stick Figure
02-09-2012, 05:49 AM
spacers were only a half inch, so roughly 1" lift on them. Still has a lot of rake when it isn't overloaded with a trailer or something. I'm probably going to change the front shocks to 5100's in the near future to bring the front up a bit more.

Stick Figure
01-25-2013, 03:59 AM
I tend to update this thread well not very often at all, so lets post a barrage of pics to catch it up again.


Finally got off my *** and made a set of rear end links to match the fronts I've been running.



I never actually had an issue with the stock ones on the rear other than them being a little out of geometry for my lift, but I was pleasantly surprised after the install. Its hardly fair to compare 198k stock parts to new, but the truck actually has a good more nimble feeling to it on the road now.

Next up

took a quick weekend trip to Yosemite No real off roading, but it did make for a handy home for the night....






Next big change was the "hide a bed"


Full write up... http://www.expeditionportal.com/forum/threads/88294-started-my-3rd-gen-4Runner-quot-Hide-A-Bed-quot-build

I wasn't at all happy with the tie down method of the fridge in its new location and the old location wasn't much better ...


but at least the straps weren't pulling on the cheap plastic handles at an angle. So a change had to be made.

The new design:



This will give me something a bit stronger than the plastic handles to tie down to and move the straps much lower to give me a little be better use of the space on the sides of the fridge. Cut outs were only for weight reduction and the "cool" look.

final addition for this update

I wanted to carry extra fuel for a trip this year. We have had issues in the past (usually with a trailer) with the fuel gauge getting wonky at the wrong time, and then conviently fixing itself before we get it home to diagnose it. I picked up a pair of 2 gallon Rotopax cans to remedy this. I wasn't 100% sure how or exactly where to mount them at the time, so I didn't buy any mounts until I had made a decision.

From when I actually built it:

Saturday I finally came up with how I wanted to do it and the only place I could find the 1" x 1" square tubing neglected to tell me they stored it outside in the rain, so the frame work took a LOT of clean up. Originally I had thought about building my own mounts but after the bed, the fridge mounts, new drivers seat foam. and a bit of maintenance i was getting tired and running out of time so I was all set to give in and buy the Rotopax mounts but of course 4wheel parts was out of stock on them. So I was back to making my own.

the result:





I ended up just replacing two of the stock cross bars with my part and securing it with just regular bolts rather than the tie down points the stock cross bars use. I know my method isn't quite as quick to remove as the Rotopax version, but it was cheaper, available with out leaving the shop, and does provide a bit more security than the standard mount that they sell.

If you are thinking of doing this, I'll warn you ahead of time that the roof is not nearly as flat as it may look. My 1" x 1" square tube is actually scalloped at the center up to 1/2" for clearance. When I welded the new material in to the cut outs, I managed to tweak it a bit more (in the right direction thankfully) to give even a bit more clearance.

I still need GOOD pics of the Rotopax mounts, but you get the idea.

and for more pics you can see a lot in my mini trip report: http://www.expeditionportal.com/forum/threads/93712-a-few-pics-from-our-recent-California-gt-Nebraska-trip

01-25-2013, 04:43 AM
I really like how you did your roof setup, bravo!

I may steal some your ideas if thats ok with you.


Stick Figure
01-25-2013, 04:48 AM
Steal away ... let me know if you have any questions

02-05-2013, 06:04 PM
Just to clarify what i am seeing here....

You have a small piece of flat steel that slids into your stock roof rails, with a bolt protruding upward though it, and a large piece of flat steel on top that clamps down on the stock roof rail?

I dont have a stock roof rail to look at, and im trying the get this all figured out so i can start on this project when i get home.