4runner+Flippac

[thebrassnuckles]

I just picked up a Flippac, and I plan on shoehorning it onto my 1st gen 4runner.:wings:

I'll get pics tomorrow..

The Flippac is an older one off a import longbed.. it is the correct width, I just need to cut about 8" off the front and fabricate a passthrough to get a good seal on the back of the cab where the factory top seals...

I dont think it'll be too hard...

seeing as I have never done anything like this and I have never fiberglassed before...:Wow1:

so... thats the plan...

comments?

questions?

 

[Overland Hadley]

Sounds like a good project.

:lurk:

 

[thebrassnuckles]

How does one remove the top folding portion of the flippac? I want to remove it so it is lighter so I can move it around easier and stand up inside while I'm reshaping the front portion.

 

[elcoyote]

How does one remove the top folding portion of the flippac? I want to remove it so it is lighter so I can move it around easier and stand up inside while I'm reshaping the front portion.

You will need to unload the torsion bar, that is done by positioning the top (bed) vertical, i.e halfway though its travel. The following instruction about replacing the torsion bar will shed some light on what to do. It's not easy and you'll need some help. A gantry or a block & tackle on a beam would be helpful

http://expeditionportal.com/forum/showpost.php?p=433287&postcount=5

 

[austintaco]

You will be my hero when you finish this project. I am sure I am not the only 1st gen owner that has wanted to do this.

 

[thebrassnuckles]

You will be my hero when you finish this project. I am sure I am not the only 1st gen owner that has wanted to do this.

I read one too many thread asking if it was possible. I decided. It's time to find out. I'm a both feet kinda guy. I'm pretty handy. Sometimes my work comes out looking good. Sometimes it's functional at best. But I am gonna try to make this one look good.

I saw the flippac for sale and I couldn't resist.

I do not have a torsion bar. At all. I already called at and whoever it is that makes the flippac. They won't have any in stock for a month and they are $285.

 

[thebrassnuckles]

OK, so I am trying to decide on the proper construction techique for restructuring the front part of the camper..

does anyone know how the flippac is built? like is it a plywood structure that is flassed on both sides? or is it a single layer of fiberglass or is it fiberglass over a foam core?

I am trying to work out a plan for building the pass through, and I need to know what material to build it out of
any help would be great.

Thanks
Bill

 

[thebrassnuckles]

here is the flippac and the cuts i am needing to make, i need to move the front wall back 8"

 

[SilverBullet]

Almost looks like a short bed FP would be perfect for you. Might want to look at the design of those for inspiration, since you ended up with a long bed version.

 

[thebrassnuckles]

Almost looks like a short bed FP would be perfect for you. Might want to look at the design of those for inspiration, since you ended up with a long bed version.

yea, the 4runner is supposed to be identical dimensions to the sb 2nd gen pickup, but with the way the camper shell attaches to the back of the cab, I think it may need to be a few inches longer.

I am thinkin about just making the cap seal out of some thinner ply wood bent around the edge real well and then take another shee of plywood and cut it to fit the shape of the cap seal..

lets see if i can paint shop a pic i have of my runner...

 

[thebrassnuckles]

heres an extremely ghetto paint of what i'm gonna try..

 

[billy bee]

here is the flippac and the cuts i am needing to make, i need to move the front wall back 8"

I don't know about the construction. But it does appear that you are removing a section of the FP critical to its overall structure. I know you will be replacing that front bulkhead section with a 4Runner cab, but be careful handling the unit once you make those cuts. I have a FP manufactured in 2003. It is far from overbuilt. Your earlier unit may be stronger, but I think the sides would be compromised if subjected to any lateral racking motion at all. It'll be easier to do if you remove the flip lid and tent components. Should be easy as the torsion rod is gone.

If you have not looked it over already, look at Bella's build thread. He was dealing with the back end of the unit rather than the bulkhead/front end. Still may give you some insight.

Good luck. Looks like fun.

bb

 

[thebrassnuckles]

I agree with you 100%

I need to figure out a way to remove the top portion of the shell to relieve some weight, I havent had a chance to open up the top at my house yet, with the lack of torsion bar its real heavy, i need to build a better stand than its on right now, lower and with wheels. then I should bve able to get the leverage I need to open it up.

I night tr building an x pattern temporary crossbenber inside the shell and bolt it to the bedrails and clamp it to the top opening or the windows to prevent anything from getting out of alignment also..

I think I will also lay down a couple extra laters of fiberglass on the inside of the srtucture to make up for the loss of strength, and I am going to build the new front part of the shell from 3/4 plywood so it should be pretty strong....
I hope..

I need to find a place locally that sells the bendable plywood for the cab seal, or I could try to bend some heavier marine grade plywood with steam and bolt it to the top and let it dry out and hopefully retain the desired shape.

I would prefer to do the latter and I thing I could get a better attachment to the front valance of the top when the time comes.

 

[thebrassnuckles]

another thought I had, after reviewing several other folks build threads would be to leave the length as is and modify the current front valane to fit the 4runner, and just build an extension box that makes the rear ensclosed, but that would probably come out looking like crap..

 

[thebrassnuckles]

talked to my buddy, he used to race sailboats when he was in his teens, he said he has lots of experience with fiberglass and that he'd love to help me out with that part of the build. :wings:

sweet!