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post #1 of 27 (permalink) Old 11-09-2011, 06:32 AM Thread Starter
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Cage Redo

When I originally built my cage, I was in a hurry since EC4RJ was a day or two away, so I made some compromises with the rear section of the cage and tied it into the stock bar. I never liked it so it is time to change it up. Thanks to Jordan for hooking me up with some 1.75" DOM, I am now ready to start. Last night I started with this.

Two hours later I ended the night with this.

Doesn't look like I did much, but I also have my cage foot plates installed and am ready to start the mockup.

Plan is to have a verticle C-Pillar behind the rear seats with a D-Pillar angles down at the back of the body. To tie the two sides together, I may just go with a simple straight tube or go with a halo type tube with two kickers. Bending will start this Sunday at Skid Row Skid Plates R&D shop in Carlisle. I have done some other work with Eric in the past with skid plates and he agreed to dust off is hydraulic bender and bend some tube.

At this point I may just get the sides mocked up then put the 4 Runner in the back of my shop to sit for the season since we picked up this 89 pickup for stupid cheap, but it needs a little bit of TLC here and there.


Plan is to get it back on the road and use it as a hauler with the eventual plan to maybe swap some parts into it. Also hoping to finally tear into the FJ40 fo rthe engine and transmission swap since the transmission finally came back from the rebuild shop. Going to be a busy winter.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #2 of 27 (permalink) Old 11-09-2011, 09:47 AM
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Looks good JT!

Wade is driving the Tacoma now.

02 Tacoma Xcb 4x4 , runnin 32"s, SkidRow Tcase skid , AOR sliders , Daystar 2.5" spacers, Downey HD 1.5" shackles, 20# CO2 setup

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post #3 of 27 (permalink) Old 11-09-2011, 10:48 AM Thread Starter
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Holy crap I cannot picture him driving now. Lets get him on some trails

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #4 of 27 (permalink) Old 11-09-2011, 12:34 PM
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Bastard I want another 3rd gen

You lower your seats yet?

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post #5 of 27 (permalink) Old 11-09-2011, 01:20 PM Thread Starter
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You'll really hate me when I tell you we paid $750 for it and it runs like a top with a low mileage 22re. Just a little rust on the bend, but the cab is 100% and the frame is about 99% rust free. We picked it up from a local guy who's the original owner and his daughter used it to take her kyaks to the river. Little bit of work and it will be a great truck.

Yep seats are about as low as they can go while keeping the sliders. Plenty of headroom now. At least for me. Only way to get them lower would be to get rid of the sliders, but then I wouldn't be able to see over the dash and hood

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #6 of 27 (permalink) Old 11-11-2011, 12:22 AM
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Quote:
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Holy crap I cannot picture him driving now. Lets get him on some trails
Yup they grow up quick.

He wants to learn to wheel safely, but for now the paved road is my focus.

02 Tacoma Xcb 4x4 , runnin 32"s, SkidRow Tcase skid , AOR sliders , Daystar 2.5" spacers, Downey HD 1.5" shackles, 20# CO2 setup

2010 Tundra DC 4x4 Longbed

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post #7 of 27 (permalink) Old 11-14-2011, 06:02 AM Thread Starter
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Fab Day 2

Got the tubing bent up at Skid Row in the morning. Finished up the frame mounting plates and started to set the tubes in place. Got the main structure tacked in as well. One issue I am running into is that my original cage is made from .120" wall tubing, but the tube I am using for the new section is .125" wall so I can't use the same inner tube sleeve that I normally use, which would be 1.5" DOM.

I have some 1.5" x .25" DOM left over from my steering linkage that I am going to have half turned down to fit in the 1.75" x .125" DOM that I am using. Once I get them turned down, I can fully weld everything out. I have about 7-8 more tubes to install, but this is how I left it at the end of the day yesterday.




JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

Was
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post #8 of 27 (permalink) Old 11-21-2011, 07:59 AM Thread Starter
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Short Fab Day 3

I got some 1.5" x 0.25" tubing turned down to fit as a slug between the two sections of tubing and installed them with plug welds. Added a few more tubes, two of which took a decent amount of time to get just right. Also notched and re-bent the original tube in the middle to intersect with the new horizontal bar of the C-pillar. Three to five more tubes and it is done. Here are the pictures.




JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

Was
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post #9 of 27 (permalink) Old 11-21-2011, 05:09 PM
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Looking sweet!

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I'd be willing to bring a lawn chair and assume a "management" position for a little while
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post #10 of 27 (permalink) Old 12-12-2011, 01:22 PM Thread Starter
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Got some more done Sunday morning. Where I placed my C-pillar on the inner fenders there was a bump that located the stock roll bar that made it a PITA to have a level area for a foot plate. Little bit of work with the plasma and some plating and I had a flat area to work with. I had Kris at After Midnight Fabrication locally cut me some nice foot plates. Got those bolted in and bent up the C-pillar and welded it out. Rolled it out of the shop to get a beter look at what I had - if the cage looks lopsided, don't worry it is not, I parked on a hill and suck at taking pictures




All that is left is to tie the rear portion of the cage into the frame, install a few gussets at the C-pillar like I have on the B-pillar, C-pillar and C-pillar to D-pillar braces, and a flip up storage/gear rack once some of the parts come in from RuffStuff.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #11 of 27 (permalink) Old 12-12-2011, 05:08 PM
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Looks good JT

It's Stock I swear





Worry when we stop busting your balls

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post #12 of 27 (permalink) Old 12-13-2011, 05:56 AM Thread Starter
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Thanks Jordan. It's getting there.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #13 of 27 (permalink) Old 12-13-2011, 04:29 PM
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Almost ready to test it out

94toy truck

Ton's links and slinky's

>>>>> www.rightcoast4x4.com<<<<<

02 dodge Ram 4.7 partly stock
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post #14 of 27 (permalink) Old 12-14-2011, 09:30 AM
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looks tight

>> DAVE <<
MINION---->> 2007 FJ CRUISER All Pro Sliders
]

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post #15 of 27 (permalink) Old 12-16-2011, 07:17 AM Thread Starter
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Thanks guys. I was nearly done with notching the remaining tubes and installing them last night and ran out of wire on the second weld Picked up the metal for the gear rack yesterday on my way into work, jsut waiting for RuffStuff to deliver the other parts to build it and should be good to go.

Probably wont be an update till after the holidays as I need to finish up some work on the 89 pickup that requires it to be in the shop, so the 4 Runner will be in storage for a little bit.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

Was
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post #16 of 27 (permalink) Old 01-29-2012, 07:51 AM Thread Starter
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Have had a few moments to get some stuff done. The cage is all welded out and bolted in. Got the rear rack built and installed. I put it on poly bushings at the one end so that I can lift the tailgate side up to access underneath for tools and straps. The top has the HiLift and will be getting an Artec TrailCrate, CO2 Tank Mount, and cooler mount - all done, just not mounted yet.



Also started on cross-bracing the B-pillar. Three more tubes under the harnes bar and that is done too.


JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #17 of 27 (permalink) Old 01-29-2012, 08:03 AM
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How close is that tube to your head?

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>>>>> www.rightcoast4x4.com<<<<<

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post #18 of 27 (permalink) Old 01-30-2012, 06:17 AM Thread Starter
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Quite a few inches, I had lowered the seats 3" since the last time you sat in it and moved them slightly forward. The B-pilar bracing is well behind my head - Should be enough to have 3" with a helmet on if I were to start racing/competing

I will try to get a picture when done.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #19 of 27 (permalink) Old 02-03-2012, 12:45 PM Thread Starter
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Picked up a new roof section for the 4 Runner over lunch today. May be able to get a windshield back in this rig at some point. The roof section is mint with no rust what so ever, but I am going to have to redo my front overhead spreader bar since the roof section I picked up has a sunroof

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #20 of 27 (permalink) Old 02-08-2012, 06:30 AM Thread Starter
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Worked on getting the roof section cut up for install, thank god I have a plasma cutter. The passenger side is being a pain, but I should be able to get it mostly lined up. It's not going to look like new when I am done, but it will work. Downside is the sunroof latch hits the center overhead tube big time and maybe the B-pillar, so I have to figure out what I am going to do with those. Probably could have gotten it welded up last night, but my plasma cutter decided it didn't want to play anymore Closest service place is an hour away - hopefully I didn't blow the board, which I don't think I did since everything else functions correctly, just the pilot arc does not start.

Anyway here are pictures so far.


JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

Was
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post #21 of 27 (permalink) Old 02-08-2012, 07:11 AM
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Looking dryer already

Make sure the glass hole is the right dimensions before you weld it. You cant really bend glass but you can form metal.

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>>>>> www.rightcoast4x4.com<<<<<

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post #22 of 27 (permalink) Old 02-08-2012, 07:27 AM Thread Starter
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Will do, it should be pretty close right now from the previous measurements I took. Any tricks for getting the left over windshield urethane off? Was going to try a stripper wheel.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #23 of 27 (permalink) Old 02-08-2012, 03:40 PM
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How much clearance do you have with that cross bar over the dash? Hard to tell from the pics but looks like it's gonna be kinda tight. Looks good though, man, maybe you'll be able to wheel in the winter again

88 Pickup 3VZ 5spd SAS on 35s, flat bed, 5.29s, Tacoma rear axle, soon to be E-Locked front, on board air, winch
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post #24 of 27 (permalink) Old 02-08-2012, 04:21 PM Thread Starter
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The dash tube is close on the drivers side, but it should clear the curvature of the windshield, I hope

I may just do a snap in windshield for the time being since I have the material.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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post #25 of 27 (permalink) Old 02-08-2012, 08:31 PM
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Quote:
Originally Posted by jtaco1 View Post
Will do, it should be pretty close right now from the previous measurements I took. Any tricks for getting the left over windshield urethane off? Was going to try a stripper wheel.
A stripper wheel should work, it comes easier cold than warm IIRC.

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>>>>> www.rightcoast4x4.com<<<<<

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post #26 of 27 (permalink) Old 02-09-2012, 09:03 AM Thread Starter
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I'll give it a shot, if not I also have a wire wheel.

No new progress other than trying to figure out the issue with my plasma. Looking like the Pilot Arc relay may have let go or had a short in the torch, which fried the torch.

JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

Was
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post #27 of 27 (permalink) Old 02-27-2012, 06:57 AM Thread Starter
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This part of the project is done otherthan maybe putting a windshield in it, but I probably won't. Once I get my plasma cutter back from repair I will finish off the B-pillar bracing. The motor also needs a good tune up and timing chain replacment - who wants to help



JT

DD - 05 Toyota 4 Runner
Trail Rig - 88 4 Runner with dual cases w/ 4.7's, 37" PB Rockers and no lift

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