1st Gen 4runner + Flip-pac

[JasonRedwood]

Would expanding foam be an acceptable filler/insulator for that gap?

I thought about that... I dont know much about expanding foam. I wonder, for the most part, if expanding foam is closed cell. I wouldnt want to trap moisture or other stuff in there. I thought about expanding foam and fiberglass combo. This weekend we are going figure this one out.

 

[trump]

Personally, I would get HDPE 2x4's (or the most suitable size) and either epoxy it to the bottom of the Flip-pac or glass it in place. However, my solutions are rarely cheap.

 

[JasonRedwood]

Personally, I would get HDPE 2x4's (or the most suitable size) and either epoxy it to the bottom of the Flip-pac or glass it in place. However, my solutions are rarely cheap.

Never heard of the stuff till now. I really like the idea of milling down hdpe to fit the contour of the 4runner rails. Its really not that expensive considering how little of it i would need. If things end up going south after we finish our current route i will use hdpe.
Thanks Trump

 

[trump]

Never heard of the stuff till now. I really like the idea of milling down hdpe to fit the contour of the 4runner rails. Its really not that expensive considering how little of it i would need. If things end up going south after we finish our current route i will use hdpe.
Thanks Trump

No worries. These 4runner/Flip-pac combos are sweet. There's a really nicely built 1st gen 4runner down the street from me... I will be in a tough spot if I ever see a for sale sign in the window.

 

[JasonRedwood]

Inching along

This last weekend we made a little bit of progress. Looks like we are about to be to the point of glassing the two tops together.
Its gona look ugly before its gets pretty...

Here is aluminum rail with the brackets rivetted.

Notched out area on flippac rail for bolt access.

Interior view of 4runner rim bolted in place next to where the Flip-pac will sit.

Aluminum L bracket that will be riveted and or screw the 4runner rim and Flip-pac together.

Afterwards all bonding and transitions will be fiberglassed over.

On a side note, I seemed to have found a leak. Seems that water might be getting in from the rear latch that holds the top down.
Or maybe it is getting in from the front torsion bar hinge and making its way back to the rear. Im not sure that water could get all the way down the side from front to back though. I plan on keeping it covered and dry. Hopefully after a few good hot summer months I can reseal it with silicone having minimal moisture in there.

 

[dorton]

I'm loving this build. I'm looking forward to seeing your progress.

 

[JasonRedwood]

The ball joint quick disconnects came in today. Planning on replacing the snapped torsion bar, similar to what Timber has done.

Pictures of Fiber glassing attempt 1.0 to come after the weekend.

 

[upcountry]

"Pictures of Fiber glassing attempt 1.0 to come after the weekend."

Looking forward to this. Having repaired many surfboards, I can only imagine what a larger scale glassing effort would be like.

Love the creativity in making an awesome custom setup.

BTW....where did you get the quick disconnect for the sway bar??

 

[JasonRedwood]

"Pictures of Fiber glassing attempt 1.0 to come after the weekend."

Looking forward to this. Having repaired many surfboards, I can only imagine what a larger scale glassing effort would be like.

Love the creativity in making an awesome custom setup.

BTW....where did you get the quick disconnect for the sway bar??

I liked the design of the ones at http://www.midwestcontrol.com/series.php?id=21.
Mcmaster.com also has an amazing selection of everything.

 

[JasonRedwood]

This can of worms is moving at a snails pace. Last weekend I sanded just about all the edges to be bonded. Rain in the forecast this weekend so there wont be any progress.
The lines and proportions are perfect in my eye.

 

[ab1985]

Loving it! If I ever see a flip-pac in this side of the U.S. I'm snatching that thing up for my 4Runner.

 

[Jeff@QuadShop]

Loving it! If I ever see a flip-pac in this side of the U.S. I'm snatching that thing up for my 4Runner.

Not if I see it first! :sombrero:

 

[Toyotero]

That's looking good man!

 

[suntinez]

This can of worms is moving at a snails pace. Last weekend I sanded just about all the edges to be bonded. Rain in the forecast this weekend so there wont be any progress.
The lines and proportions are perfect in my eye.

I agree! In fact I can't stop thinking about doing this to my 88 4runner. Thanks for blazing the trail

 

[Jeff@QuadShop]

I agree! In fact I can't stop thinking about doing this to my 88 4runner. Thanks for blazing the trail

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