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Discussion Starter #1
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.
 

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Looks good JT!

Wade is driving the Tacoma now. :(
 

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Discussion Starter #3
Holy crap :eek: I cannot picture him driving now. Lets get him on some trails :D
 

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Discussion Starter #5
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 :)
 

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Holy crap :eek: I cannot picture him driving now. Lets get him on some trails :D
Yup they grow up quick.:(

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

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Discussion Starter #7
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.



 

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Discussion Starter #8
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.



 

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Looking sweet!
 

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Discussion Starter #10
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.
 

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Discussion Starter #12
Thanks Jordan. It's getting there.
 

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Discussion Starter #15
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 :mad: 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.
 

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Discussion Starter #16
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.

 

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Discussion Starter #18
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.
 

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Discussion Starter #19
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 :)
 

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Discussion Starter #20
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.

 
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