1st Gen 4runner + Flip-pac

[JasonRedwood]

Not if I see it first! :sombrero:

I recommend using http://www.allofcraigs.com/ when searching for used anything. Thats how I found mine. Love that site!

Thanks guys, this custom mod is frustrating but its gona be well worth it.
If I was to do it over I would find some of the HDPE(plastic lumber) and mill the piece to fit like TRUMP suggested.
Its very difficult to find any HDPE in California thicker than 3/4". I only found one place in Cali that sold the 3/4" stuff.
The one company that would ship the $12 piece to me wanted over $200 for shipping. I guess because of the 6 foot length...?
My route might prove to be fine though, we will see after it hits the trails

There is another guy here that put one on a white 1st gen a few years aso. There's a build thread somewhere.

Yeah Brassknuckles is doing the flip-pac conversion as well. He has a young child so I would imagine that things move at a different pace. My dogs can just sit and watch me. ha

 

[Jeff@QuadShop]

I use www.searchtempest.com

 

[Caoboy]

HDPE as in High Density Poly Ethylene?

If so, TAP Plastics makes a bonding agent for polyethylene. You could always bond boards together and then mill out what you need.

 

[JasonRedwood]

HDPE as in High Density Poly Ethylene?

If so, TAP Plastics makes a bonding agent for polyethylene. You could always bond boards together and then mill out what you need.

Yeah, High Density Poly Ethylene.
Thanks for the info. Ill keep that in mind.

 

[thebrassnuckles]

I

Yeah Brassknuckles is doing the flip-pac conversion as well. He has a young child so I would imagine that things move at a different pace. My dogs can just sit and watch me. ha

Young children. Ha ha.

Also, work has been insane lately. Lots of weekends. But it should calm down soon enough. Hopefully.

 

[JasonRedwood]

Got the 4runner forward rim attached to the flip-pac today. We used aluminum angle to bridge the two pieces. After using the g-flex system to glue the angle to both campers we riveted and screwed the angle to the ajoining fiberglass. Tomorrow the fiberglassing over everything begins.


Just having the angle bonded to everything made the whole fusion very rigid. With the fiberglass its going to work out great.

 

[ab1985]

It's really coming together now.:victory:

 

[JasonRedwood]

Baby steps. This is my first time fiber glassing. Took more time and materials than I expected but its getting there.

 

[dorton]

Hows it coming? Had any time to work on it?

 

[JasonRedwood]

Hows it coming? Had any time to work on it?

It hasn't had any progress on it. Came down with Bronchitis a couple weeks ago, got over that recently.
Im getting hitched on the 18th so most of my extra time is going to the preparations of that.

Believe me there is not a day that goes by that I don't think about it. HA

On a side note, I have some still new in box headers from Downey Off-Road, heading towards my house as we speak.:wings:
Also might have my long travel suspension coming soon...

 

[JasonRedwood]

ALL GLASSED TOGETHER

Got the Flip-pac bonded to the 4runner rim this last weekend!
I'm really happy with the West System G-flex sytem, amazing stuff.



Next weekend I plan to put 2-3 more layers on the top inside transition for extra support.
After the next layer of glass on the inside I plan on using an epoxy/resin clay to pretty up the fiber glass before paint.
May end up using bondo depending on how the clay tests with everything.

Removed the old torsion bar that was snapped and replaced with stainless steel nuts and bolts. Also a milled graphite impregnated brass bushing to through the center of the camper arms.


I dug out the silicone and saw plenty of erosion on the inside.
The plan as of now is to let the pre-siliconed areas air out for a week then inject gorilla glue as deep as we can get it. Gorilla glue expands and cures when exposed to moisture. The hope is that the glue will fill any voids and dry out the innards as much as possible. After the glue I will cover the area with marine silicone.

I welcome any and all suggestions.

Jason

 

[ab1985]

I welcome any and all suggestions.

No suggestions here. Just taking lots of notes and wondering where I can get my hands on a flip-pac on the east coast.:drool:

 

[thebrassnuckles]

Awesome! Looks great!

 

[Clutch]

Are you replacing the torsion bar with gas struts instead?

 

[JasonRedwood]

Are you replacing the torsion bar with gas struts instead?

No it will manual labor that Im replacing the torsion bar with.