[T4Tools]

I've been fabricating a lot of parts for my second 4runner project. I almost finished my first when it was totaled after someone ran a stop sign and the only pic I have is of the accident. So I thought I'd document more this time.

2001 Sr5 with 198,000 miles
-FJ wheels w. 265 75r16 tires
-Spacer lift 2.5 inches I think, (came with truck)
-Custom rear bumper
-Custom welded-on rock sliders
-Custom hitch
-Leather rear seat from my 98 limited

I'm building a sort of expedition rig like my last one. Custom raised roof, lowered rear floor for stepping in and things like a 120 volt generator, microwave, sink and coffee machine. The look will be kind of an armored military vehicle meets work truck. Its one of those things you'll have to see since most of it is in my head and on my welding table. Here's the earliest photo I have of the project (I tend to start customizing things as soon as I get them home).

[T4Tools]

I'm building everything modular, so I can do all the design and welding indoors while I'm driving my truck everyday. Then I can weld them on and they will hopefully plug together. On my first truck I started with the roof, then the back entry doors and generator mount. Now that it's totaled, the next piece ready to go on to the new truck is the back back doors.

I'm getting rid of the hatch for a traditional door that carries the spare tire. This opens up the bottom for a lowered floor. To the right is a security cage for an ex2000 Honda generator. Above that is a door that becomes a table when opened. The first photo is the skeleton and the second is a rough painted version. I originally had lexan plastic windows, but then I figured I'd go all the way, tore them out and put in 1 1/2 inch bullet-proof glass.

[T4Tools]

I fit most of the glass inside the frame, but I had to fabricate trim to seal the raised portion. Then I made silicone gaskets and after some paint, started to do a trial-fit. Of course that's when you notice all the things that don't quite fit the way you expected. I originally planned on keeping the stock tail lights, but it pushed the doors back and the generator stuck out past the bumper too far. This meant I had to add back up lights. I found some 4 inch led lights and made a pod so I could mount one in front of the spare tire.

[T4Tools]

Here's a pic of the backup light and spare tire handle. One thing I learned is that it's very hard to keep the tolerance of six lug nuts when you're welding them to two parts with enough steel to hold a truck tire. Gotta love heat stress. As of now I have the back section mounted on the truck and just finished lowering part of the rear floor. I'll try and get some pics and details up soon.

[BrianSD_42]

SUBSCRIBED!

I had to look at the pictures twice because I couldn't believe what I was seeing.

Can't wait to see more.

[4eigner]

Cool project, but how much weight do you anticipate all of this will add? Is the drivetrain up to the task with the expected weight gain, not to mention the power plant? Or are there planned upgrades for those as well?

[ranbar02]

Well you've got my attention. I've never seen anything like it except on military applicatons. I'm ready to see the finished product.

[Kryptoroxx]

Sub'd

[LittleCaesar]

I am amazed you get get all that fab equipment into your garage.

Looks nice.

[Brveagle]

Wow you are talented.

[T4Tools]

Thanks for the comments. You all made my morning. I've been wanting to share this with the community here for a while. Here's a pic of how it sits right now. The next project is sealing it in and fabrication of a stainless table. As for weight, it looks heavier than it is. Most of the panels are 24 gage foam filled.

[cdrewferd]

Can't wait to see more pics.

[wake_rider]

Man, raising the roof is something I've always wanted to do, but I just don't have the fabrication equipment, or more importantly, the skills or experience. I've always thought a bubbled top similar to those on a Landrover Discovery would be amazeballs on a 3rd gen, especially if it could be done to look completely factory/stock.

Imagine that top added to the stock height of a 3rd gen, opening up another 8 inches in head room and giving constant vision out the top while in the back seats or the rear trunk space. Man, that would be fantastic.

[jer7440]

Subscribed!

[Bandit Runner]

Wow! This is insane, but very cool. Definitely subscribed.

I can't wait to see how you transition from the curvy OEM sheetmetal to that straight-lined door.

This site needed something exciting like this.