chapolito's 97 manual Baja Surf Camper build

chapolito said:

I've been loving the chalk bag water bottle holder, but when we go on trips, both my wife and I bring our water bottles, which leads to one rolling around. Added a second bag:

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What a great idea. I could use this in more than just my 4Runner... (I use the rear cupholder in my Volt since the front ones get in the way of my arms, my Camry cupholders are in the way of the stereo, etc.)

-Charlie

Mark_BC said:

Fluid Film isn't a pain to work with once applied; pretty easy to remove any grunge with a wire brush. Way easier than dealing with rust.

It will stink like sheep in the heat.

I have found that it only lasts a few months. But I have rain here which washes it off. I think bacteria eat it since it is a natural product made from sheep.

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I haven't minded the smell so much. It isn't hard to work around, except that I kept bumping into the frame while under the car this weekend and it was getting all over my clothes.

Let me know how that mix works. I have been trying out CRC Heavy Duty Corrosion Inhibitor, which lasts much longer and dries to a wax, but I'm hesitant to go spraying it all over the under carriage. I'd like to be a bit more targeted since it is kind of hard to remove, but perhaps I'm over thinking it.

phattyduck said:

What a great idea. I could use this in more than just my 4Runner...

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My wife asked if she could have one for her RAV4 after I installed it in the 4Runner.

chapolito said:

I've had the energy suspension steering rack and sway bar bushings sitting around for over a year now, and I finally got them installed this weekend. Took a lot longer than expected and whew did those torque specs kick my ass. Thought I was going to yank the truck off the jack stands.

Most everything I've done I can't notice a difference, but I was pleasantly surprised to feel less body roll on turns. Will need to spend more time on the highway to see if the vibrations go away.

Looks like one of the three was already poly:

Pick-n-pull set a 2000 3RZ two days ago, but the entire engine bay had been stripped clean by the time I got there. dang! I did score a set of OEM clear headlights, so the projector retrofit project will get bumped up the list, especially with winter coming.

Repainted the hub caps...real lipstick on a pig situation here.

I've been loving the chalk bag water bottle holder, but when we go on trips, both my wife and I bring our water bottles, which leads to one rolling around. Added a second bag:

Click to expand...

I've got two radios (GMRS because that's what everyone but my wheelin buddies use, and CB because my wheelin buddies are stuck in 1975) hanging off the side of the console there ...but I like that enough that I might have to ditch the CB so I can stash my nalgene. My buddies don't come four wheeling with me much anyway.

Was on the road for a month hunting waves in Peru and checking out the Inca sights. Slow progress on the 4Runner, but good memories.


Got the projectors installed in the junkyard headlights, output is sooo much better.


Went with the Acme super H1 projectors—install was really straightforward. The project took a long time, but went without issue. Nice and relaxing...if only all projects could be like this!


Upgraded the windshield sprayer nozzles to Honda ones:


I'm 36 and I've only ever owned 3 cars in my life—86 4Runner, chopped 72 VW Squareback, and this 97 4Runner. The 4Runners were hand-me-downs from my parents. The VW was my first project car out of college...a horribly impractical choice considering I didn't have a garage. I also wasn't prepared for the ongoing cost of the hobby. Owned it for a couple years and then sold it even though I did enjoy working on it. I share this because I ran into this old photo of the VW with the 4Runner in the background:


And lastly, I picked up a DC TIG welder + tank and cart!

I have no welding experience, but I'm excited to learn. Next project is to properly fix the roof rust, and then start fabricating.

Been preparing for the next Baja trip right after Christmas. Original plan was to focus on getting all the rust repaired, but welding ended up being much more difficult than I was expecting, and only got as far as fixing the floor pan. The roof will need to wait...probably until summer.

Pulled off all the rear trim and assessed the damage. This used to be the corner where I put my wet booties—years of saltwater wasn't pretty.


Started by tackling the rust that wasn't too deep. Lots of wire wheeling. Took a nice big chunk of skin off a finger at one point.


Cut out the really bad section. At this point the car was getting annoyingly loud to drive (still my daily driver).


Got to welding, decided it would be easier as two panels. Really slow going, and barely any decent weld pools. I gave up on the rear side, the metal was so thin and rusty.


Second panel went better. I spent more time fabricating the patch to fit snuggly, and I switched from the hand pedal to the foot pedal.



Replaced a tie down with a non-rusty one from the junkyard.


All cleaned up! Still have a square hole to cut for the scuff plate and the 4th tie down to bolt in, but waaay better. I have been going a little wild spraying fluid film on areas that I know are going to start rusting or that I wasn't able to address fully.


I was at the junkyard and saw a '99 with tan rear quarter panel trim that had the rear 12v socket and the larger storage compartment. To make the passenger side fit I had to cut out a section of the body:


Four test fits and some paint and I ended up with this:


It fits! The color matches the other trim exactly, but that piece was darker oak on 97s. Swapped the 12v charger for USB ports that will run off the house battery.


I chipped the corner of the A/C button pulling it out a year ago, and pulled a replacement off a T100


Unfortunately the color is slightly different.


With all the trim off it was a good opportunity to remove the rear heater

Good welding on those patches.

Just curious, What started the floor rot in that area? Cross member rot out below? Hole got a pin hole in it? As I haven't seen one rot there. Mostly they start on the seam up by the back of the rear seat. I seen several start rotting there.

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brillo_76 said:

Good welding on those patches.

Just curious, What started the floor rot in that area? Cross member rot out below? Hole got a pin hole in it? As I haven't seen one rot there. Mostly they start on the seam up by the back of the rear seat. I seen several start rotting there.

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He said it in the post - wet surfing booties. Imaging putting a few ounces of salt water in that corner regularly...

-Charlie

phattyduck said:

He said it in the post - wet surfing booties. Imaging putting a few ounces of salt water in that corner regularly...



-Charlie

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Ah yep. That will do it. Imagine driving through salt water for several months a year. Just haven't seen one rust there before. Sorry I missed that part..

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My floor is crusty in the same spot, probably from a combination of wet surfboards for two decades and then four years of road salt with beat up pinch welds.

Do you ever roll the hatch window down and shove longboards in? My rear hatch has some rust and the window felts are absolutely shot from that, but I can't find new ones to replace them.

thezentree said:

I've got two radios (GMRS because that's what everyone but my wheelin buddies use, and CB because my wheelin buddies are stuck in 1975) hanging off the side of the console there ...but I like that enough that I might have to ditch the CB so I can stash my nalgene. My buddies don't come four wheeling with me much anyway.

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I finally got around to doing this. What a great little mod!

I need to find a place to mount my GMRS radio now.

thezentree said:

Do you ever roll the hatch window down and shove longboards in? My rear hatch has some rust and the window felts are absolutely shot from that, but I can't find new ones to replace them.

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Yes, all the time. But we pretty much always put towels down or have the boards in a bag, so the felt isn't too banged up. Drove like this from San Diego to San Francisco, not sure why we didn't put them on the roof, probably didn't have enough straps.


Probably all the lumber has been worse for the felt...

thezentree said:

I finally got around to doing this. What a great little mod!

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Awesome! Just a little pricey at $35/bag.

Would this help prevent the salt damage to your cargo area?
1999 Toyota 4Runner Cargo Mat & Trunk Liner - Custom Fit For Cars, SUVs, Minivans | WeatherTech

If this works its a fairly inexpensive way to keep from having floor panels rot. That is if it will work for your application of the surf boards. Maybe its not a solution. Just a thought.

brillo_76 said:

Would this help prevent the salt damage to your cargo area?
1999 Toyota 4Runner Cargo Mat & Trunk Liner - Custom Fit For Cars, SUVs, Minivans | WeatherTech

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Yes, it absolutely would. I built a dedicated wetsuit/bootie drawer a couple years ago that has plastic bins, has kept the cargo area much dryer and cleaner.


Thinking of getting the driver/passenger front weather tech though, they seem like a good fit.

chapolito said:

Yes, it absolutely would. I built a dedicated wetsuit/bootie drawer a couple years ago that has plastic bins, has kept the cargo area much dryer and cleaner.

Thinking of getting the driver/passenger front weather tech though, they seem like a good fit.

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Lots of folks swear by those mats. Very nice rig and making it your own.

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From the same junkyard 99 I pulled the rear quarterpanel trim, I grabbed a scuff plate replacement because I had snapped the tabs on mine. Interesting to see that they added foam around the connectors in later years, wonder why?


When I had the hole in the floor, it made me notice a metallic rattling noise at the lower end of each gear coming from the exhaust. Poked at all the heat shields until I found the culprit: some of the welds on the aftermarket catalytic converter (stolen in 2011) came loose. Slapped a hose clamp on it and no more rattle. I still get pretty strong vibration in the exhaust still at times, not certain what the cause is.


Replaced the fan clutch, which felt like it had seized. The new one feels very similar, so I'm guessing it was fine. at 305k, it was probably closer to the end of it's life than the start, so I'll just tell myself it was preventative.


With the rear heater out, I riveted in the fire extinguisher holder. Has been loosely bungeed to the passenger seat for the last year. In my VW Squareback
the brake master cylinder caught on fire once—I luckily was carrying an extinguisher.


During our last trip the fridge overheated, so I added in two computer fans to the electronics cubby. If you are wondering what that stain is—I spilled a gallon of orange paint back there ~15 years ago in college.


Originally I was thinking to have them turn on when the compressor was running, but that was outside of my skill level. So I hooked up the switch from the rear heater to a relay that turned them on. Means we'll need to manually control when they turn on, but at 0.4w each, I think it is fine to keep them on continuously when we're on a trip.


Had to increase the height of the platform by 3/4" to fit the fridge, but it was really snug, and I needed to remove the rubber feet to make it fit. Increased it another 1 1/4" to allow for additional airflow and reinstall the feet. Will need to build a fascia around the fridge and rebuild the drawer fronts to clean up the look.


Almost ready for the next trip!

Another successful Baja trip!

This time, the fridge was great, no overheating, and no food poisoning, just cold Tecates. Installed the Renogy BT-2 bluetooth module to monitor the 50a MPPT charge controller. Was nice to be able to understand what the Solar/alternator was charging at.


My calculations had the daily usage around 40Ah, but was pleased to find it only needed to charge ~20Ah/day. I'm sure that would be more if it was cooling in the heat of summer, but there would also be more sun available. Really would like to get the solar panel permanently installed, having the cable snake out from the door is a pain.






Another last minute upgrade was replacing the rear hatch latch and strike plate. The rear hatch had to be slammed to fully close and the door function of the cargo light wasn't working. Old strike plate was fairly crusty:


Coated the new strike plate and hatch with cosmoline—CRC Heavy Duty Rust Inhibitor. Really like this stuff, but I did have some of it flake off the latch when I cinched up the bolts.


Installed, looks way better, and now the hatch completely closes without effort.

While I had the bumper taken apart I installed the four cam engineering cabin air vent. And liberally applied fluid film everywhere.

Nice truck!

Chuckles89 said:

Nice truck!

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Appreciate it!

Chuckles89 said:

Nice truck!

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Agreed - one of my favorites on this forum!

Surf13 said:

Agreed - one of my favorites on this forum!

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Very kind of you, thanks!