Java's 4th gen Runner

java

Expedition Leader
OK I dug into this lat night. I have been wanting projector headlights, but OE ones have not been fourth coming on my local CL. One of the GRM guys mentioned The Retrofit source was having a clearance on some projectors, so I snapped up a set, and found some used non projector headlights to use.

For some reason I decided to start this after 8 last night, supposedly takes 4 hours to do... I was bored and it was indoor work.

The new headlights I got were a little yellowed across the top, a little rubbing compound and the trusty HF buffer and it looks a lot better. May need some clear on it.

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Step 2, stick it in the oven. 250 for 8 mins in my case. Dont touch the metal bits when it comes out. Get all needed parts. Projector, shroud etc. Wear gloves, much easier than trying to get every little finger print off the chrome bezel. There will still be some.

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Pry, curse, drop it because its 250 degrees until the lens is separated from the housing. In my case I needed to pull the lens straight out, there is a bit of trim attached to the inside of it, that catches and breaks if you dont....

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Next remove the little covererator for the end of the halogen bulb. Wiggle tear whatever.

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Then projector goes in the bulb hole, carefully threading the high beam wires through. And tightening the nut on the back.

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Bulb holder is then attached, definitely adds some rigidity also.

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Shroud clips on the front.

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Back in the oven to re melt the glue and press back together. remember it comes out hot...

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Repeat for second side, you know since its late and the first one went well.... Break the second one, fight it all back together and...

broken tabs....


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A little 5 min epoxy and wa la!

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Now to install if it stops raining and see if I got the projectors remotely straight....


Not a great pic as its an angled wall, and im aiming uphill, but whatever. Cutoff is GREAT, the projectors need to be tweaked a little to get them perfectly flat, but that should be easy. Drove past a friend of mine and he said they weren't blinding. Cutoff is right at the trunk line on most "standard" sized cars in traffic.

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java

Expedition Leader
Trans cooler done.

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Shroud back on.

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Actually makes a huge difference. Took a long twisty windy road with lots of elevation gain and loss and it peaked at 203 unlocked in 3rd after a long climb.
 

zidaro

Explorer
Longer sway bar end links have been needed for awhile. I hit a retread off a semi last weekend and found that one side has come loose, nut gone and threads toast. Sound like I need to do it sooner rather than later now.

Cut new threads into the old link, they are a little shallow, but hopefully will work.
Cut it in half, its 3/8" solid rod.
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Cut a piece of tube to sleeve it, total length ~1.25" longer than stock.
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Drill holes, plug weld.
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Welded the ends too, forgot to take pics...
finished with some paint.
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Love it! simple. Im stealing your idea :)
 

java

Expedition Leader
Rejected.

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We did make it to a nice spot to camp though, it was a couple miles of snow drifts in the shade, and they were getting deep.... Camping with snow behind us. It was nice, but got chilly at night.


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OLDSKING

New member
great build man! Looks like you are running a Rola roof basket with a roof top tent? any close up pics of how you have it installed cause I have one on my 3rd gen 4Runner and have contemplated installing one but was nervous with strength
 

java

Expedition Leader
great build man! Looks like you are running a Rola roof basket with a roof top tent? any close up pics of how you have it installed cause I have one on my 3rd gen 4Runner and have contemplated installing one but was nervous with strength

Yep its an old Rola. I may have pics somewhere, but its basically 1/4" angle iron bolted to the inside of the factory rails so the basket sites 1/16" off the roof in the center. I did weld the basket together as it leaked nasty rusty water constantly. No issues with it so far, its been that way for a few years now. I do want to get something a little bigger though.
 

jeffryscott

2006 Rally Course Champion: Expedition Trophy
great build man! Looks like you are running a Rola roof basket with a roof top tent? any close up pics of how you have it installed cause I have one on my 3rd gen 4Runner and have contemplated installing one but was nervous with strength

I too would like to see some close ups of the angle iron adapters you made. Nice 4Runner, just bought an 04 myself and am looking to make some changes!
 

java

Expedition Leader
I too would like to see some close ups of the angle iron adapters you made. Nice 4Runner, just bought an 04 myself and am looking to make some changes!

Ill see if I can find some, all my old photo hosting died, and I just put the tent on so you cant see them! :)
 

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