[Lamer]

Originally Posted by RMGulchin1

Next to-do list:

- Front & Rear bumper removal (just broke the heads off of a bolt on the front and back so great start. Will have to machine those out probably). Plan is to undercoat the insides of the bumpers then apply plastidip and clear coat.

- Been scouring the internet for a low profile, sort of cheap roof rack. I just need to mount a rifle box and Hi-Lift. Want to extend the current roof rack about 6 inches longer also.

- Very minimal rust underneath the car. Just a few spots. Going to wirebrush them anyway and apply rustoleum undercoat.

The CURT roof racks are usually cheap on craigslist and can be mounted lower using simple hardware. food for thought.

[TwinDadRunner]

Nice progress. I just picked up a 97 a couple weeks ago. And had to do head gaskets. Luckily they weren’t blown so no damage. Got it back out and running today. Now to do the LED interior lights because I can afford that lol. Keep up the great work will be following.


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[RMGulchin1]

Originally Posted by Lamer

The CURT roof racks are usually cheap on craigslist and can be mounted lower using simple hardware. food for thought.

Haven't seen these yet, thanks for the rec!

[RMGulchin1]

These things were sagging up to 50% in the cold this winter. Super quick, super easy swap.

Picked em up here: Amazon.com: Qty (2) Toyota 4Runner 1996 1997 1998 1999 2000 2001 2002 Rear Hatch / Liftgate Lift Supports Struts Strong Arm 4286: Automotive

$40 for the two of them. KINDA disappointed they did not come with replacement hardware too though.

Ladder worked great for holding it open while I worked. This thing is heavy, definitely recommend the ladder (or other inanimate support).

[RMGulchin1]

Attempted to remove the stock roof rack to check it out and also the front and rear bumpers: stripped bolts / broken heads everywhere.

Plan is to remove the front/rear bumpers, then wash/sand/& undercoating on the whole thing (as well as the hitch). This should hold them over until I can get some new ones. Also replace all the hardware that I can get to while in there.

What's the best way to get stripped bolts, stuck bolts, and broken heads out if I plan to replace them anyway? I've been trying an EZ-Out kit but it hasn't done jack squat.

Note to self: end caps for the roof rack rails-
00278-35967 front left roof rack cap
00278-35968 front right cap

[RMGulchin1]

Recently finished removing the entire rear bumper assembly, side bumper panels, and everything pertaining to the spare tire rack under the rear.

A couple busted knuckles and about 20 seized bolt extractions later and everything was apart.

I gave all the metal a good wire brushing, and sprayed everything with undercoating spray (including the insides of the bumpers which were the worst). Outside of the bumpers sprayed with around 6 coats of plasti-dip.

Not bad! I don't love it, but it will suffice until I can get an aftermarket replacement (and it was CHEAP).

Next step I guess I'll be slowly moving back to front, removing all seized bolts and replacing them (builds character), and brushing/undercoating all the metal I can get to.

[RMGulchin1]

Other thing I did was went ahead and mounted a roof box onto the "stock" roof rack.

Used this as a guide: Using a Gun Case as a Cargo Box for Recovery Gear on Roof Rack

Basically I only need this for light duty (some tools, recovery stuff, random cargo). It's only 36". I've got a sleeping platform and other things inside I need to save room for.

Got the 36" Plano box on amazon: Amazon.com : Plano All Weather Tactical Gun Case, 36-Inch : Sports & Outdoors

Must have got a deal because it was about $60 when I ordered.

Instead of drilling holes through the bottom, I drilled through the sides and fixed some U-bolts around the crossbars. Sealed with silicon sealant and used anti-seize lube on the hardware. Some cut up pool noodles between the hardware and crossbars. A waterproof test during yesterday's thunderstorms tells me that this thing holds up well (time will tell though).

Good enough for me for this summer. Eventually will want to build a low-profile rack to replace the stock one altogether.

[RMGulchin1]

Update