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Speaking from engineering theory, not actual experience - but added weight on the lid just makes it harder to flip. The stress in the torsion bar, that can, and based on anecdotal evidence eventually will, cause failure, is due to the 180 degree "twist" from closed to open. That's independent of...

I thought this was pretty good for the mainstream press (read past the mtn bike intro to see the Toyota content): http://www.bbc.com/autos/story/20141201-meet-canadas-gravity-warriors (Sorry if it's a re-post but a quick search didn't show anything) -dman93

I like that lower mounting! Like your Taco, my stock T100 bumper doesn't really lend itself to supporting the lid, since it doesn't stick out far enough for a straight tube to clear the fenders (though mine is real steel :) ). When it's light in the morning (and if it's dry) I'll check if my T...

I owned an 80 series for 13 years and 100K+ miles. When new, it seemed like a sport sedan compared to both my 4WD Ford Ranger and my brother-in-law's similarly late model Tahoe - and a beast offroad with the factory lockers, only improved a year later with an OME lift and BFG MT's. After 13...

Inspiring! It's time for me to get to work. Thanks for some good ideas.

I just checked the broken remnants of my t-bar. There's just a small blind hole, maybe 1/2" deep, at each end ... probably to help center the bar when it's manufactured.

I just checked - actually my poles are just 8' long ... 7' hammock poles with 1' extension. Here's the thread with my and camelfilter's details: http://www.expeditionportal.com/forum/threads/129940-Flippac-torsion-bar-delete-modification More than 8' may be easier to use for part of the flip...

See my posts on my t-bar delete ... I gave all those details. But there are several options, and your preference may vary. My final version uses two-poles which telescope and pin together, to provide 10' length for the tip-over process, but can be disassembled and stowed more easily than two 10'...

Arclight, putting stops on the hinges would transfer a huge amount of force into the hinge and the attachment points, due to the leverage created by the length of the lid. If the lid weighs 100 lbs, centered about 40" from the hinges, that's a torque of 4000 in lbs. if that torque is stopped at...

The link that Austintaco mentions is what inspired me to do my own calculations. The problem with the long crank, is that just like with the long helper poles that are part of the "delete" design, there's still a lot of inertia when the lid falls. So the crank will spin around fast unless...

Arclight, thanks for the Schroeder link. I'll dig up my broken bar and measure it up and get in touch with them. I had talked to a supplier of torsion bar steel in the Midwest earlier this year but they didn't have the right material. -dman

The problems with the Flippac and torsion bar setup, as designed, are two-fold. First, the torsion bar is subject to very high stress as it rotates + or - 90 degrees from the neutral position. Compare this with a typical automotive front suspension torsion bar which maybe rotates 20 degrees or...

Update I finally camped in the flipped Flip-Pac two nights this weekend. Flipped it and un-flipped it and moved in-between sites. The first night I flipped it myself and it was a little tricky coming down. I'm glad I am diligent about putting a piece of 4" think ethafoam on the roof of the cab...

My T100 has a very thin gap between hood and fender and the mounting surface on the inner fender is angled in such a way that the load is also at an angle. Rivnuts and machine screws vs self-tapping sheet metal screws might help a little but not much. My pins flex visibly. My torsion bar...

Do they still use standard hood pins, or is there something beefier there? I replaced my prop rod hardware with stainless steel marine parts but the pin attachment - to the fender on my truck - seems weak. -dman93

Nice tarp setup - and nice to see another Flip-Pac'ed T100. I just upgraded my hood struts with some stainless steel bimini top fittings, to beef them up since they're now supporting the entire weight sans torsion bar. But I'll probably add supports to my bumper just like faulke. I just couldn't...

I removed the broken remains of my T-bar, which was broken when I got the Flip-Pac. It wasn't easy (required a lot of pounding and finally a combination of heat, solvent and puller to extract) but it was straightforward. I don't know how many years it had been rusted in place. I have just...

Some pictures and a few more comments. Mounting brackets - I'd recommend locating them even further forward to get some wood behind the screws.Please, no comments about my messy sealing job. I had opened the 5200 and used some a few months back, and the tube had dried just enough that I had to...

Friday update. I don't work Fridays so spent the day fabricating the brackets (I used 2x2x1/8" aluminum angle) and buying some more materials. I basically followed Camelfilter's, Rhino's and Timber's designs so I won't post pictures. A couple of comments: - There's not much wood or metal behind...

Thanks for the links.