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Old 04-17-2020, 01:52 AM #1
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P_nlsn's '03 Offroad/Overland Build

Figured I might as well start a build thread with all the big plans I hope to one day do, so here goes nothing. To be honest, there's no possible way I'd be able to list absolutely everything I do to this thing, but I'll try. If you'd like, give me a follow on Instagram to see pics and keep up! @03.4runner

My long-term goals (long,long term, like next 6 years) are to hopefully get this thing in a condition to do some real overlanding, where it's just me and friends in the middle of nowhere, but since this is my daily-driver for a while, it's probably just gonna be built for shorter camping and off-roading trips for now

For reference, here she is stock (7/24/19):


And where she is as of 3/28/20:



Here's what I've done as of 4/16/20: (click on an item to go to the post)

-Drivetrain
1.25" Wheel Spacers (Came on it)
35x12.5" KO2's
17x9" Helo HE878 Wheels
Custom Body Mount Chop

5th Gen Powerstop Caliper Upgrade All-Around (fixes notorious frozen calipers on 4th gens, which I had in the front driver side)
5th Gen Powerstop Front Rotors (thicker than 4th gen) (4th gen rear rotors to ensure emergency brake adjustment screw hole lined up)
Powerstop Z36 Brake Setup All-Around

-Suspension
3" Toytec Boss Lift Kit
JBA High Caster UCA's


-Interior:
Dash/Instrument Cluster LED swap to red
Various painted interior trim pieces

-Sound
Kenwood Excelon DPX593BT Radio
1000W 5ch JVC KS-AX3205D Amp
6x9" Kenwood KFC-6966S Speakers in front
6.5" Kenwood KFC-1666S Speakers in rear
8" 250W Rockville W8T4-S2 Sub

Uniden CMX760 CB Radio
Uniden B7 Speaker
4' Firestik II Antenna

-Exterior:
3" 4crawler Body Lift
Generic Roof Rack (Came on it)
Custom 3D printed front emblem
Various stickers

-Major Planned Mods/Future Hopes: (not all, just major)
Coastal Offroad WIY Front Bumper Kit
Custom Steel Rear Bumper with Spare Tire Carrier (possibly jerrycan/high-lift carrier too?)
Bigger/Stronger Roof Rack
Full Skids
Regearing Axles
Snorkel
Rock Sliders
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

Last edited by P_nlsn; 07-17-2020 at 01:53 PM.
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Old 04-17-2020, 02:07 AM #2
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Sound System

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Kenwood Excelon DPX593BT Radio
1000W 5ch JVC KS-AX3205D Amp
6x9" Kenwood KFC-6966S Speakers in front
6.5" Kenwood KFC-1666S Speakers in rear
8" 250W Rockville W8T4-S2 Sub
One of the first things I did was upgrade/replace the sound system. The front driver speaker was busted, and I was going to just replace that, but then I decided to just replace it all.



The speakers I put in were Kenwood KFC-6966S (6x9") in the front door, and Kenwood KFC-1666S (6.5") in the rear door. My headunit is a Kenwood Excelon DPX593BT, and the amp is a JVC KS-AX3205D. The subwoofer I have is a Rockville W8T4-S2 (PO put it in). I also put in the Axxess ASWC-1 Steering Wheel Control Adapter so I could keep the functionality if the factory controls. Crutchfield's ReadyHarness made the job a ton easier.



Not gonna lie, this thing sounds great. I feel it's the perfect amount of bass to be able to feel it and enjoy it, but still not too overpowering and doesn't quite make you "that guy"

The amp is mounted under the passenger seat, it's grounded to the seat mount, the power wires for it are run under the center console, and he ReadyHarness was run alongside the factory harness in the floor.







Parts List
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

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Old 04-17-2020, 02:16 AM #3
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Lift + UCA's

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3" Toytec Boss Lift Kit
JBA High Caster UCA's
The Toytec lift was pretty simple to install. Not much went wrong or gave us problems




The JBA UCA's are great. I haven't had any problems with them, and my alignment is perfect. The install for them went smoothly too



The rear springs and shocks were pretty easy to put in too



The kit also came with a front diff drop, which was insanely simple to install

However, the skid plate spacers that it came with didn't exactly fit, so I used them where I could, and then for the middle driver side, where the diff mount is squared, I just used the bolt the kit came with, and then two nuts I found lying around the garage to act as a double spacer to fill the gap





Parts List
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

Last edited by P_nlsn; 06-19-2020 at 01:13 PM.
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Old 04-17-2020, 02:46 AM #4
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Body Lift

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3" 4crawler Body Lift
Now the body lift wasn't bad, but it definitely gave us some trouble. Going up 3" with a body lift is pretty rare (Honestly, Roger said I was the first person to order a 3" from him), and we kind of had to figure out part of it on our own since there's not much documentation for it (besides the instructions that the lift comes with). The main problems I found were the bumpers, gas pump wires, and the power steering lines.



The rear bumper has a solid frame gap in it



And we had to fabricate some custom brackets to be able to use the stock front bumper until I can get a custom steel one. We first designed it in Fusion 360, and then my brother 3D printed it to check it's fitment



We then used our CNC plasma cutting table to cut it out of 3/16" steel. Yes, I know this completely negates the functionality of my bumper (should I hit anything), but it's only temporary





The steering shaft extension was honestly a pain in the butt to get in there, just because it's such a tight fit at 3". Although, with some finagling, we finally got it in there. Now, the bolts on the bottom of the extension do rub the rubber boot where the shaft goes through the firewall, but it should be fine



For the powersteering hoses, we had to go to NAPA and buy some longer tubing to create some custom length ones, because the stock ones were pulled dead tight and were bending the reservoir down




The wires for the gas pump were also pulled pretty tight at this height, so I had to get to the hole under the carpet in the cab and feed a little extra through the floor

Here's the price list for the 4Crawler body lifts. I had to email him to get this, as his website only goes up to 2" / Price List
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

Last edited by P_nlsn; 06-19-2020 at 01:18 PM.
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Old 04-17-2020, 03:05 AM #5
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Tires and Wheels

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35x12.5" KO2's
17x9" Helo HE878 Wheels
Custom Body Mount Chop
I gotta say, I love the KO2's. While I would've perferred some KM3's like my brother (Cause they look dope, and perform amazingly), but due to the concerns of my dad, and the fact that this is also my daily, I went with the KO2's due to better pavement performance in rain and stuff



The KO2's are rather quiet, and do great in the mud. I think they might be some of the best A/T's out there.

The body chop wasn't bad, it was just a lot of re-trimming to try shave as much off as possible



After chopping it and making sure the tires would *mostly* fit in all ranges of the suspension, we welded a steel plate to help re-strengthen the mount



Then we painted it to help prevent rust and corrosion





Shout out to my brother for welding it (@masonnelson.photo on IG)




Here's a link to the KO2's and HE878's / BFGoodrich KO2's - Helo HE878's
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

Last edited by P_nlsn; 06-19-2020 at 01:24 PM.
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Old 05-10-2020, 05:38 PM #6
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Another offroad trip in ONF

Just got back from camping with my brother (IG: trail.blazer05)

I love my rig more and more each day and it never ceases to amaze me. Had a blast and attempted to take some decent pictures

>Instagram Post Here<





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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

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Old 05-25-2020, 05:45 PM #7
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Interior Color Swap

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Dash/Instrument Cluster LED swap to red
Recently finished up my interior LED swap! It looks amazing in person! I just used some left over red LED's and resistors that my brother had from doing his interior, but for the instrument cluster, I had to buy some SMD's

I just removed the stock "twist-in" bulb, and soldered the new LED's, along with a resistor, directly onto the boards/prongs

I will admit, it does have some hot spots/dim spots in the clock/climate control switches because the spread of the lights I had isn't perfect, but it still looks great



I started with just the driver window backlight. I can't remember what voltage the circuit used, but it might've been 12v (be sure and check for you're self though)



And then the climate control, clock, and clock button backlights. Now, I'm pretty sure I remember the circuit being 6v, but I can't say for sure because I didn't write it down like the others.





The Switches took some engineering to make everything fit, but it all worked out ok. All the stock switches took 12v

-The Center Diff Lock switch has the positive on the outermost side
-The DAC switch also has the positive on the outermost side
-The 4WD selector has the positive on the bottom-most side (also the longer prong)
-And the Rear Window Switch has the positive on the shortest prong



Next up was the instrument cluster and steering wheel controls



It's just a bunch of SMD's - I used these LED's

If you're wondering what LED's do what and stuff - here's what I found:

-All the SMD's get 2v
-Every LED is labeled on the circuit board

(Yes, I know positives are marked, but to make it easier to identify, I note which side too)

RPM Backlight
-Bottom Light
-LED 56
-Positive = Right side
-Top Light
-LED 58
-Positive = Right side
RPM Needle
-Bottom Light
-LED 60
-Positive = Bottom
-Top Light
-LED 59
-Positive = Right side
Odometer Backlight
-LED 57
-Positive = Top

Speedometer Needle/Backlight
-Left Light
-LED 53
-Positive = Bottom
-Top Light
-LED 71
-Positive = Right side
-Right Light
-Led 54
-Positive = Bottom
Gas/Temp Gauge Backlight
-Bottom Light
-LED 55
-Positive = Top
-Top Light
-LED 61
-Positive = Bottom
-Middle Light
-LED 72
-Positive = Bottom
Gas Gauge Needle
-LED 62
-Positive = Bottom

Temp Gauge Needle
-LED 63
-Positive = Bottom

I also changed the cup holder light and the shifter light too, just so they matched



It was easy to do, you just twist out the old light assembly, then I popped the old light out and stuck the prongs of the new LED behind the metal contact plates in the socket. I used hot glue to ensure it stayed in place and didn't pop out. Since the LED takes less voltage than the circuit gives, I spliced a resistor into to the wires and covered it with heat shrink



Lastly, my glove box light was already burned out, so I went ahead and made it red too



I used a pretty similar technique as what I did with the cup holder light. I Soldered the resistor to the LED, then shoved the prongs behind the metal contact plates, then hot glued it down and bent it down so it'd fit inside the casing

One last note - Be sure the dimmer control knob is plugged in when you go to test your lights. I wasn't thinking about this when I went to test my newly installed lights, and most of them didn't come on. Practically every dash light get's its power through this knob, so don't be dumb like me and freak out over nothing
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"

Last edited by P_nlsn; 05-26-2020 at 01:50 AM.
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Old 05-25-2020, 07:35 PM #8
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Quote:
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Recently finished up my interior LED swap! It looks amazing in person!
The lighting swap looks really good! It's going to be my summer project... I think, not sure if I'll have the time. Some good info and pictures. Thanks, and keep up the good work
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Old 05-26-2020, 01:43 AM #9
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The lighting swap looks really good! It's going to be my summer project... I think, not sure if I'll have the time. Some good info and pictures. Thanks, and keep up the good work
It really does, I prefer it over the stock orange any day! It doesn't take that long, as long you know what you're doing. I think the main time consumer for me was figuring out how to do it all (like voltages, positive, how to place the lights, etc - and then troubleshooting when something didn't work right). It also helps save time when you don't mess up the stepper motor for the speedometer like I did (oops ). Also, one thing that I wasted some time on (and I actually just added this to my post because it's ridiculous, but could happen to others), is if you have the light dimmer control in the upper dash unplugged, most of the lights won't work. I know that might sound obvious, but I wasn't thinking about and freaked out when the lights I just replaced weren't working when I went to test them

I'm glad the info helps! I try and document/explain a good portion of the things I do so others can use it to aid their projects, so it's nice to hear it actually helps. If you come across any questions or need some help when you end up doing it (or any other time), please feel free to ask!
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4wd V6 2003 Sport 4runner w/ 308k miles // 3" Suspension Lift + 3" Body Lift on 35" K02's // @03.4runner // Build Thread

"Don't worry, I'm a professional idiot - I've been doing stupid stuff my whole life"
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