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Old 07-22-2019, 05:07 PM #1
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Globetrotter Build!

Since I'm a newbie to the forum (and 4Runners in general) I had to pay my dues with comments, contributions, and such like everybody else before I could start this thread.

Let me go on record to say this is literally the first "truck" of any sort I have ever owned (and I'm 41). I have been a sportscar guy from day one. I had Hondas, Mustangs, Audis, and most recently my beloved Maserati GranTurismo. I have been turning wrenches with my father for as long as I can recall. I was a 5.0 guy, I was a Fast and Furious ricer and everything in between and I loved all of it.

I had my '13 Maserati for 5 years and put 68,000 miles on her, which for an exotic is almost unheard of but that car is pure sex every time she roared to life. The time came for a new adventure so I sold her a few weeks ago and have moved into the world of offroading/overlanding and 4Runners. The one thing I missed most from the Maserati days was the lack of things I could do to it (tastefully, its a Maserati after all). The only notable engine/performance mod available was a THIRTY SIX THOUSAND dollar supercharger to gain a piddly 100hp. That's just insanity.

Now I find myself in a 4Runner and am absolutely FLOORED with all the amazing and CREATIVE things you guys do to/with these vehicles(Antman was unreal!). I can only hope to learn from you guys as I go along. I will try to show the improvements I make to my truck as they come and maybe somehow be of inspiration to others in trade.

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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-23-2019 at 03:22 PM.
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Old 07-22-2019, 05:17 PM #2
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Ok, so I bought myself an '18 Pure White SR5 as my adventure project car. I went the SR5 route to save a little money since I knew my first step was gutting the stock suspension. My research here has already given me the insight towards the components I wanted and a basic plan of attack.

The first day she pulled into my garage I had a nice little collection of parts waiting for her. Up on the jack stands she went.

Pro grille (cheap Amazon version, worked well for the price)
Icon 2.5 Exten Travel with Res.
JBA UCAs
Icon 2.0 Rears (resevoir versions were backordered for almost 2 mos)
Dobinson Springs coated red to match the UCAs.
Kicker 6.5s
Attached Images
Globetrotter Build!-20190625_210745-jpg  Globetrotter Build!-20190629_141913-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-23-2019 at 03:32 PM.
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Old 07-22-2019, 05:19 PM #3
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I have those same Icons, it took a bit of fabrication to get them to fit.
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Old 07-22-2019, 05:24 PM #4
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The install was dead easy.

* I didnt take install pics since its very well detailed step by step in the instructions. The only step that WASNT clear in the instructions was to REMOVE THE SKID PLATE dont just try to wiggle your fingers in there to install the sway bar blocks.

I did the front install in a matter of a few hours. The only part that necessitated help was needing my wife to slide the LOOOOONG UCA bolt in the hole while I held the JBA shims in place.

Both pieces are gorgeous to behold. I adjusted the collars to 1 3/4 inches and that gave me a 3" lift and balanced the higher rear springs.
Attached Images
Globetrotter Build!-20190630_202703-jpg  Globetrotter Build!-20190706_094202-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

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Old 07-22-2019, 05:29 PM #5
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Quote:
Originally Posted by LandCruiser View Post
I have those same Icons, it took a bit of fabrication to get them to fit.
Really?? I was floored just how smoothly the whole install went on mine. I usually end up with one bolt taking 3 hours to free or some part not fitting properly.

I really had nothing slow me down except the instructions not mentioning to remove the skid plate and I spent more time than I should have trying to finagle the sway block bolts into place before I said screw it and dropped the %^& thing. The opposing side went like butter after that.
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!
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Old 07-22-2019, 05:37 PM #6
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I also did the high clearance bumper chop right away. It startled my wife to see the huge chunk of bumper lying on the ground after only owning the car for a few hours! LOL

I chose to do the contoured chop (see the way it curves in toward the center) as seen on Trail4Runner.com. I liked that it flowed better from the front view than a hard line would. I also didnt cut QUITE as high as SSO suggested. I used 2in painters tape, followed the front angles and cut below the tape. I cut the fenderliner surplus plastic and used my heat gun to reshape it to bend backwards into the new space and ziptied(classy)
Attached Images
Globetrotter Build!-20190704_092136-jpg  Globetrotter Build!-20190621_195635-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-22-2019 at 05:46 PM.
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Old 07-22-2019, 06:02 PM #7
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I dont sit still well.

Having a little extra play money from the sale of the Mas kept the wife from fussing (too much) about buying parts right away. Soooo I did more stuff...

Almost immediately upon seeing the 4Runners I was incredibly disappointed to see the poor quality of headlights for a vehicle of this year. I decided I would change out the low beams with Sealight LEDs (rather inexpensive but well reviewed) off Amazon and some yellow LEDS for the fogs. I also got the yellow laminex film since I also like the yellow look when off.

The Sealights had a fitment issue which is apparently common with a lot of LEDs due to the large heat sink. When I tried to screw it in, the diameter of the sink wouldnt allow it to seat properly since the headlight framing gets in the way JUST BARELY. Its always just barely! So after considering returning them I decided, ya know what, I bet that 1/8" of aluminum heat sink in that one little section in the way isnt going to make or break the situation sooooo I ground it off on the bench grinder.

Et Voila! This is the way it should have looked from the factory!!
Attached Images
Globetrotter Build!-20190621_200529-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 08-05-2019 at 02:01 PM.
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Old 07-22-2019, 06:33 PM #8
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I have replaced the interior speakers with Kicker 6.5s all around. I also put 3.5s in the dash though that required more work and creative cutting of the factory frame than I think will be justified. The Kickers were affordable and sound great once amplified. My days of building big money stereo systems are behind me so these will suit me fine. I am in the process of building a fiberglass subwoofer enclosure for a 10" CompR into that right hand rear pocket. I will post pics in a bit.
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!
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Old 07-23-2019, 01:35 PM #9
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Sub Enclosure Build

So, given my inability to just let a good thing be I decided my next project was to build a subwoofer enclosure. I had built fiberglass enclosures for several of my vehicles in my younger years but Im about a decade out of practice. There was a lot of trial and error and a bit of having to accept the imperfections of inexperience.

After seeing the absurd prices of the premade stealth boxes on the market I decided, like others here, to build it and put my enclosure in that weird side pocket on the right.

The first and most critical step in working with fiberglass is to remove EVERYTHING that could possibly be ruined by inevitable resin drips. DO NOT RELY ON CAUTION OR A STEADY HAND!! Resin is sticky as hell, messy to work with and it will permanently damage the finish of almost anything it comes in contact with in a car. Resin must also be mixed very accurately to avoid curing issues. I removed the rear carpet and foam padding down to the bare metal. The next step is to tape off the area to be glassed using 2in Painter's Tape. Be sure you leave a buffer space well beyond your working area to allow for errors or runs. Once I had a layer covering the entire surface I laid a few more layers across seams to ensure there was way the resin could permeate. Given the design of the pocket I bridged some tape across the descending opening otherwise you'd never be able to remove it once hardened. Some people use aluminum foil between the painters tape and the resin layer since foil tears easily and will make removal much easier. In hindsight, I wish I hand done that!! Even though painters tape releases easily, in that quantity and pulling horizontally its MUCH more stubborn.

My plan was to have the box wedge securly in that pocket and seated in that tray where the anchor is thus allowing me to use the anchor bolt hole to secure the box from inside. Due to the location I knew I would be relocating the outlets elsewhere(TBD). This location was preferable over the left side which would block access to the bottle jack. Once ready to go, the next step is to begin laying TORN(not cut) bits of fiberglass MAT(not cloth). With each bit laid you'll DAB your CAREFULLY MEASURED resin on top until the fiberglass appears to dissolve into the resin. Any areas subject to gravity its best to paint a coat of resin directly on the tape first to aid in the adhesion of the glass, then dab more resin. Continue this process over the entire working space for several layers (3+) and extending well beyond your intended final edges. This will allow for trimming and sanding down to the proper shape. I failed to do this adequately in the footing area and its obvious in the final product. Like I said, sometimes you have to accept the flaws of inexperience and do your best. Still beats $750 for a box!
Attached Images
Globetrotter Build!-20190714_103328-jpg  Globetrotter Build!-20190714_114812-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-23-2019 at 04:03 PM.
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Old 07-23-2019, 01:37 PM #10
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Once the layers have hardened, carefully though it WILL require some force, try to seperate the shell from the body paneling. Remove as much of the tape as possible; some will remain and that's fine. Trim your edges with a dremel to match your body panel lines. Admire your handiwork. The next steps are the tedious bits. You are going to lay more and more fiberglass on the INTERIOR of your shell. With each layer make sure you are dabbing out as much air between the layers as possible until each becomes transparent. Resin takes only minutes to gel and become useless so dont mix large quantities. The resin lid is designed to be your tray and is a good amount for each batch. BUY THE GALLON OF RESIN AND LOTS OF GLASS! You will use it. As the layers harden and more are laid you will see the thickness growing. You want about 1/4 inch all around. Thicker is fine but try not to be thinner.
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Globetrotter Build!-20190714_210219-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!
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Old 07-23-2019, 01:39 PM #11
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Once you have a nice strong shell get out a dremel or grinding wheel and cut off the feathered glass edges and any runs that occured on the outside of the shell. An angle grinder will eat fiberglass MUCH easier than a dremel but use finesse. Now cut the woofer ring from MDF, you can get the dimensions from the speaker manfacturer. I stacked 3 rings to get the strentgh and projection I wanted. Using dowels and hot glue(and an extra set of hands) measure the dowels to support the ring at the desired depth and height. These dowels are not REALLY structural but will need to adhere strong enough to support the tension of the felt that will be stretched over it. Test fitment in the vehicle again.
Attached Images
Globetrotter Build!-20190717_210725-jpg  Globetrotter Build!-20190717_210700-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!
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Old 07-23-2019, 01:43 PM #12
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You can see at this point of retesting fitment that the foot angles back into the tray. I also should have extended the glass shell closer to the taillight opening for better shape.....oh well. I could have remedied but it would have required a lot more glassing and my laziness overpowered my OCD.
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-23-2019 at 04:09 PM.
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Old 07-23-2019, 01:48 PM #13
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Now is when the box truly starts to take shape!!! With hot glue gun in hand, run a thick bead of glue along the top edge of the box. Adhere any cheap normal crafting felt (1 yard was sufficent for this) along the back edge as you glue. Make your way down the sides, keeping the fabric taught. With this box shape I needed curvature from the top to the front edge so I bought a small bag of polyfil (pillow stuffing) that had a cylindrical shape and filled the void nicely and I draped the felt over it knowing I could remove the bag of poly later. As you begin to glue the bottom, now is the time to ensure everything is tight as you go. the face of the ring should be smooth and tight. Make strategic cuts as necessary for any areas that bunching is unavoidable until they lay flat. Now comes a LOT more resin. You want to saturate the felt completely and along all edges. Once saturated, lay glass in a few layers over the felt for added rigidity. There is no need to glass the center face of the ring since it will be cut out but make sure you glass over the ring area itself. Once cured, test the tesion of the felt, it should be nice and solid but not done. More layers are likely needed to get to the 1/4 inch depth.

Once all that is done and thoroughly cured use a sander and HIGH GRIT (80) paper to smooth the finish sufficient to knock down hardened drips or uneven surfaces. Use a dremel or multitool to cut out the ring face. Add more glass anywhere the thickness is lacking. In small batches mix up automotive bondo and smear it over the face of the sanded glass. Bondo is FAR easier to sand than resin and will allow for a smooth finish suitable to hide fluctuations in the glass and to soften the curves of the box. Sand smooth once cured and test the fitment again. This will be the final look for your box.
Attached Images
Globetrotter Build!-20190719_005229-jpg  Globetrotter Build!-20190721_114753-jpg  Globetrotter Build!-20190721_172444-jpg  Globetrotter Build!-20190721_203620-jpg 
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-23-2019 at 05:22 PM.
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Old 07-23-2019, 01:51 PM #14
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The last stages are drilling holes for the anchor bolt and washer to seat, another for the wiring itself, and (possibly) a port if volume is a lttle too big for sealed enclosure. Both holes should be sealed with silicone afterwards. I will adhere polyfil to the inside if I need a bit more air volume but I doubt that to be the case.

Once all holes are drilled NOW you can carpet...that's the step I'm at now. Ill keep you posted with pics and tips if the carpet presents any issues.

I fully admit I am not a professional and well out of practice but that said I am quite pleased with the final product (except that foot LOL).
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*2018 White SR5 4x4, Icon 2.5 Exten Travel w/ res, JBA High Caster UCAs, 1.25 Spidertraxx, SSO Sliders and Bumper (on route), Icon Rebounds and 285/70 Falken Wildpeak A/Ts
*2013 Maserati GranTurismo Sport
*2013 Fiat 500 Abarth- the rocket powered go-kart!

Last edited by Globetrotter78; 07-23-2019 at 05:04 PM.
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Old 07-23-2019, 02:34 PM #15
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Quote:
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Since I'm a newbie to the forum (and 4Runners in general) I had to pay my dues with comments, contributions, and such like everybody else before I could start this thread.

Let me go on record to say this is literally the first "truck" of any sort I have ever owned (and I'm 41). I have been a sportscar guy from day one. I had Hondas, Mustangs, Audis, and most recently my beloved Maserati GranTurismo. I have been turning wrenches with my father for as long as I can recall. I was a 5.0 guy, I was a Fast and Furious ricer and I loved all of it.

I had my '13 Maserati for 5 years and put 68,000 miles on her, which for an exotic is almost unheard of but that car is pure sex every time she roared to life. The time came for a new adventure so I sold her and have moved into the world of offroading/overlanding and 4Runners. The one thing I missed most from the Maserati days was the lack of things I could do to it (tastefully, its a Maserati after all). The only noteable engine/performance mod available was a THIRTY SIX THOUSAND dollar supercharger to gain a piddly 100hp. That's just insanity.

Now I find myself in a 4Runner and am absolutely FLOORED with all the amazing and CREATIVE things you guys do to/with these vehicles(Antman was unreal!). I can only hope to learn from you guys as I go along. I will try to show the improvements I make to my truck as they come and maybe somehow be of inspiration to others in trade.

Welcome..
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