4X4 Noobie Needs help with EXPEDITION 4RUNNER Project Plans

[KokaneeRanger]

Speaking from experience here as a person who has built a truck specifically for long distance unsupported vehicle dependent expeditions, I can tell you that there are some things on your list that are just bling and would be unnecessary for the expedition traveller.

A couple questions first...

First question: Where will these expeditions be?

If you bring a blinged out truck to most 3rd world countries, you will attract attention that you don't want, and will probably be robbed / extorted on multiple occassions.

Second question: How long will these expeditions be?

If you are going somewhere truly remote, you will need to put less junk on your truck in favor of more weight carrying capacity for supplies. My truck is very heavy with bolted on junk, so I made a trailer that can haul extra supplies (which also supports my glamping habit )


Ok. First off, that is lots of lights. With that setup, you will have serious light reflection off of the hood of the truck... an issue you will have to deal with.

Invest in recovery gear before you start tearing into the truck. People take stock trucks around the world all the time.

Increasing fuel capacity should be high on the list when building an expedition truck. The 4Runners are particularly poor in this category, but have ample room for an auxiliary tank or fuel can basket in the stock spare tire location.

You would be much better off with a Tirfor hand winch then a mounted rear winch. Tirfors can be used from the side as well, in case your best extraction line is perpendicular to the way the cehicle is pointed (which does happen sometimes, BTW). They can also serve as a backup in case your front winch goes out.

Snorkels are nice to have, but in my experience, most of the people who have them do not have properly installed snorkels. A test is to put a plastic bag over the intake head. If the truck keeps running, the snorkel is not functioninfg properly and your engine will be sucking water when it goes for a swim.

Stay relatively close to stock specifications. If you have a truck that has a highly modified drivetrain, it will be both more likely to break and more difficult to fix. Add the limited availability of parts in remote places, and your attempt to enhance your truck's capability will get you stranded. With 4Runners, choosing a tire size bigger then 33" is asking for trouble. In all honesty, I believe 265/75/R16 (32") to be the best balance of capable and reliable for the 3rd gen trucks.

As mentioned, with long term heavy use, stuff will break. Do not go on an expedition in a highly modified truck that you do not know how to work on. Period.

1. Is it possible to install a newer aged V8 in the 3rd gen? Yes, but better don't.
2. Which model would be best for me? 99, 00, 01, 02? I would recommend 99, but they are all comparable, and each has its quirks.
3. What would be better suited for my use: Limited or SR5 ? No real difference, but the limited models often have a factory rear locker.
4. In order to pass boulders from 2ft to 3ft in height, what sized tires and what size lift is ideal? An expedition with 2-3 ft, high boulders? Where are you trying to go? Its very difficult to have your cake and eat it too. See above.

I could talk to you more about this, but these type of questions will be better answered on a forum dedicated to expedition travel. Go check out ExPo.

A recent picture of my 4Runner. I would feel comfortable taking it down the Rubicon or around the world.

I appreciate your reply,
My purpose is to explore, camp, enjoy, and to photograph the back country of British Columbia. Mostly the Southwestern Portion. It is a very alpine area, with lots of steep climbs and winding river valleys with creeks and river crossings. It rains alot and there is snow most of the year in the higher elevations.
I will have to encounter and be prepared for:
-MUD
-SNOW
-GRAVEL ROCKS FROM PEBBLE SIZED TO 3 FOOT BOULDERS AND INCLUDING ROCK LEDGES
-A CONTINUOUS ASCENT UP A STEEP AND VERY ROCKY ROAD WITH SMALL STREAMS AND CONTINUOUS BOULDERS THE SIZE OF BASKETBALLS
-LOTS OF VERTICAL CLIMBING, up to a 45 degree on average sometimes more steep.
-RIVER AND STREAM CROSSINGS
-LONG AND SNAKY MAINTAINED GRAVEL ROADS
-UNMAINTAINED LOGGING ROADS

Seeing all the other 4x4'ers going up in the bush all have serious rock climbing modifications with roll cages, even tires above 40 inches. They mostly do it for the sport and challenge, While my rig will be more expo oriented, but will still require me to pass large boulders and rock ledges.... These guys will intentionally take the harder way up the mountain for the fun of it, as I would simply like to get to a very remote location, taking the easiest way up.
My expeditions will last on average a few days and possibly up to a week. I plan on traveling up to 250kms/155miles in 1 direction. MAXIMUM 350kms/220miles in 1 direction....
I like your point on the recovery equipment, I would definitely want to have anything i can that will assist me in my goal.. but I feel I will have to mod the truck extensively based on where I plan on going...
I will definitely upgrade the fuel tank and mount the spare tire on the roof rack or rear custom bumper..
Extensive lighting is a must for me, since BC is full of narrow valleys where it is VERY dark once the sun goes over the mountain, which can be very early in the evening. I plan on putting 4 lights per side and a few in the back as well as a motor controlled vertical/horizontal swiveling spotlight, in addition to the 9 I want on the front. I basically want well above average lighting on all sides and under the truck. I understand I will have to overhaul the electrical system and add more batteries.

 

[cdre]

You should be able to find a diesel 3rd gen in Canada. It used to be legal to import them from Japan. Google "Japan Partner" and talk with them about current import laws for Canada. They may be able to find you a suitable truck. I used to buy from them and ship containers of engines and trucks to Central America.

 

[KokaneeRanger]

You should be able to find a diesel 3rd gen in Canada. It used to be legal to import them from Japan. Google "Japan Partner" and talk with them about current import laws for Canada. They may be able to find you a suitable truck. I used to buy from them and ship containers of engines and trucks to Central America.

cool, if I went with a Diesel would that hamper performance versus a gasoline v6??

 

[gptoy96]

Our Canadian 15 year limit has hit the point now to include 3rd gens, IanB http://www.toyota-4runner.org/new-members/78138-just-couple-more-months.html is off to pick his up soon. This would be a perfect ride, depending on how you feel about RHD. Perhaps with this being a trail rig maybe not such a big issue for yourself.

I can't speak on performance but should be able to get more range out of diesel compared to gas.

 

[SoCal]

Extensive lighting is a must for me, since BC is full of narrow valleys where it is VERY dark once the sun goes over the mountain, which can be very early in the evening. I plan on putting 4 lights per side and a few in the back as well as a motor controlled vertical/horizontal swiveling spotlight, in addition to the 9 I want on the front. I basically want well above average lighting on all sides and under the truck. I understand I will have to overhaul the electrical system and add more batteries.

First off I'm all for going for it with your rig and hope it turns out how you want. It seems to be an awful lot of lights, dark is dark, and i can't imagine ever needing that many lights even if I was running the Baja 1000. That roof rack will be a light basket with little room for other gear. With a little more strategic planning on where and what kind of lights you could cut that number in half and save yourself weight and cost.

Have fun dreaming, planning and hopefully soon building up your 4runner.

 

[Nelsonmd]

BELOW ARE PICTURES OF SIMILAR AREAS WHERE I WILL EXPLORE:

Do imageshack pics just not show up for anyone else? Imageshack seems to either not load at all, or only partially load for me.

 

[Hepar]

Our Canadian 15 year limit has hit the point now to include 3rd gens, IanB http://www.toyota-4runner.org/new-members/78138-just-couple-more-months.html is off to pick his up soon. This would be a perfect ride, depending on how you feel about RHD. Perhaps with this being a trail rig maybe not such a big issue for yourself.

I can't speak on performance but should be able to get more range out of diesel compared to gas.

Diesel 3rd Gen! One of the things I've been looking forward the most to 2011!

 

[KokaneeRanger]

Do imageshack pics just not show up for anyone else? Imageshack seems to either not load at all, or only partially load for me.

for some reason it didnt show in those 2 posts, but it did in my first post. i use the direct link and use the img tags and it worked... only once...

 

[Nelsonmd]

for some reason it didnt show in those 2 posts, but it did in my first post. i use the direct link and use the img tags and it worked... only once...

Try Photobucket, it seems to work alot better. At least for me.

When I clicked on them, the link to imageshack worked, but the pics didn't completely load, so I saw the top half of some of the pics. They looked cool.

 

[Mr. Leary]

I appreciate your reply,
My purpose is to explore, camp, enjoy, and to photograph the back country of British Columbia. Mostly the Southwestern Portion. It is a very alpine area, with lots of steep climbs and winding river valleys with creeks and river crossings. It rains alot and there is snow most of the year in the higher elevations.
I will have to encounter and be prepared for:
-MUD
-SNOW
-GRAVEL ROCKS FROM PEBBLE SIZED TO 3 FOOT BOULDERS AND INCLUDING ROCK LEDGES
-A CONTINUOUS ASCENT UP A STEEP AND VERY ROCKY ROAD WITH SMALL STREAMS AND CONTINUOUS BOULDERS THE SIZE OF BASKETBALLS
-LOTS OF VERTICAL CLIMBING, up to a 45 degree on average sometimes more steep.
-RIVER AND STREAM CROSSINGS
-LONG AND SNAKY MAINTAINED GRAVEL ROADS
-UNMAINTAINED LOGGING ROADS

Seeing all the other 4x4'ers going up in the bush all have serious rock climbing modifications with roll cages, even tires above 40 inches. They mostly do it for the sport and challenge, While my rig will be more expo oriented, but will still require me to pass large boulders and rock ledges.... These guys will intentionally take the harder way up the mountain for the fun of it, as I would simply like to get to a very remote location, taking the easiest way up.
My expeditions will last on average a few days and possibly up to a week. I plan on traveling up to 250kms/155miles in 1 direction. MAXIMUM 350kms/220miles in 1 direction....
I like your point on the recovery equipment, I would definitely want to have anything i can that will assist me in my goal.. but I feel I will have to mod the truck extensively based on where I plan on going...
I will definitely upgrade the fuel tank and mount the spare tire on the roof rack or rear custom bumper..
Extensive lighting is a must for me, since BC is full of narrow valleys where it is VERY dark once the sun goes over the mountain, which can be very early in the evening. I plan on putting 4 lights per side and a few in the back as well as a motor controlled vertical/horizontal swiveling spotlight, in addition to the 9 I want on the front. I basically want well above average lighting on all sides and under the truck. I understand I will have to overhaul the electrical system and add more batteries.

Bigger tires will be a sacrifice to range, and the unsprung weight will turn into a problem eventually. Honestly, an 80 series LC on 35s is better suited to the type of terrain you describe. But, there is no reason you can't get there in a built 4Runner. There will be modifications needed, however:

The climbs you talk about will make it difficult to acheive power, and the altitude changes will keep your engine from running optimally. To combat this, I would recommend 5.29 gears for extra power, front and rear selectable lockers and no bigger then 33" tires. Bigger then 33" tires and you risk breaking a CV or a front diff during one of these hill climbs, and breaking a truck mid climb can turn into a dangerous situation quickly, even more so if you are alone. Keep the lockers selectable so you can maximize differentiation during tight off camber turns (handy when you are on the edge of a cliff and don't want to meet Jesus), while preserving the available traction in rough or crossed axle terrain. Brakes will be a big deal. Upgrade to Toyota Tundra 231mm calipers, because after all, you have to come back down all those steep climbs you go up. Critical kit includes one of all three belts, some sort of leak sealer (I use window sealer), a spare CV axle (and practice changing it before you get out there), and a spare alternator, and a spare radiator hose. Further I would recommend dual batteries and a battery management system. No power means you are stranded, and the second battery can be tapped during the inevitable winch pull you will need to perform out there. Type is up to you, but I will highly recommend Die Hard Platinum batteries from Sears. They are tough, strong, and have a great warranty. Management system, I recommend the National Luna split charger with monitor. You will need comm in addition to other support gear that you will have to carry. Given that so many wheelers use CB, it would be wise to have one in your truck. Also install a HAM 2m/70cm radio, and note the frequencies of the nearby repeaters. HAM has much better range then a CB, and in case you get stranded, it can spare you from having to walk out. Gear should include a comprehensive first aid kit and the training to use it. Remember, no truck is invincible and no driver is perfect. **** happens, and if you are alone you are the only one who can deal with it. It is always safer to attempt an expedition into rough and remote country with another rig (3 is a good number). Smaller tires mean that there will be obstacles that your truck cannot tackle unaided. Most of this can be overcome with a winch, some rigging, a good jack and some bridging ladders (I would recommend these, from discount ramps). If there are deep water crossings, I would recommend a snorkel, and with ARB lockers, it would be a good idea to plumb the air compressor intake into your snorkel, as well as your front and rear differential breathers. A cargo separator and stowage system of some kind would be a good idea as well, because having stuff move around the truck in transit is asking for trouble.

Pack heavy items low, and bulky items high. If you have to put anything up on the roof, it should be bulky rather then heavy.

I try not to toot my own horn, but my truck build has most of the modifications that you would want for this type of travel. Armor, relatively close to factory specs, some lift, and upgraded systems. My sig line contains a link to my build thread.

We takled a trail with some of the terrain you described on a recent trip in NW Arkansas. Here is the link.

Check out Vision X LED bars before you drop the cash on Hellas. They have a much much lower current draw and comparable light output.

Browse, learn, ask questions, then build.

 

[runn4it]

That truck looks familiar!

Well its nice to see what my truck would look like with a rack and winch bumper on it. When I first read your post I was immediately interested because I am slowly building my own expedition vehicle. When I scrolled down and saw that you had photoshopped MY picture with MY truck I was quite surprised. I am flattered that you chose my pic to "modify". I am currently waiting on a Shrockworks bumper (and already have the winch) to install later on in Feb. and will be sure to post pics when it is finished. I WILL say that the Sonoran Steel 1.2 suspension set up I have works flawlessly so far for the wheeling I do. I have a CBI rear bumper with a tire swing out, 60" extreme high lift, and gas can carrier installed and the added weight seemed to smooth out the rear suspension. You should go to http://www.sierraexpeditions.com and check out what they have for some of the "list" of things you describe. Will and his employees are passionate about 4wheeling and have a great knowledge of what works and what doesn't. Feel free to PM me if you would like to discuss more in detail, otherwise, do what most of us do and visit different forum sites, including this awesome site, with questions and gain some knowledge and ideas of what to do with your future purchase. Good luck and I look foward to seeing your progress!

 

[KokaneeRanger]

Bigger tires will be a sacrifice to range, and the unsprung weight will turn into a problem eventually. Honestly, an 80 series LC on 35s is better suited to the type of terrain you describe. But, there is no reason you can't get there in a built 4Runner. There will be modifications needed, however:

The climbs you talk about will make it difficult to acheive power, and the altitude changes will keep your engine from running optimally. To combat this, I would recommend 5.29 gears for extra power, front and rear selectable lockers and no bigger then 33" tires. Bigger then 33" tires and you risk breaking a CV or a front diff during one of these hill climbs, and breaking a truck mid climb can turn into a dangerous situation quickly, even more so if you are alone. Keep the lockers selectable so you can maximize differentiation during tight off camber turns (handy when you are on the edge of a cliff and don't want to meet Jesus), while preserving the available traction in rough or crossed axle terrain. Brakes will be a big deal. Upgrade to Toyota Tundra 231mm calipers, because after all, you have to come back down all those steep climbs you go up. Critical kit includes one of all three belts, some sort of leak sealer (I use window sealer), a spare CV axle (and practice changing it before you get out there), and a spare alternator, and a spare radiator hose. Further I would recommend dual batteries and a battery management system. No power means you are stranded, and the second battery can be tapped during the inevitable winch pull you will need to perform out there. Type is up to you, but I will highly recommend Die Hard Platinum batteries from Sears. They are tough, strong, and have a great warranty. Management system, I recommend the National Luna split charger with monitor. You will need comm in addition to other support gear that you will have to carry. Given that so many wheelers use CB, it would be wise to have one in your truck. Also install a HAM 2m/70cm radio, and note the frequencies of the nearby repeaters. HAM has much better range then a CB, and in case you get stranded, it can spare you from having to walk out. Gear should include a comprehensive first aid kit and the training to use it. Remember, no truck is invincible and no driver is perfect. **** happens, and if you are alone you are the only one who can deal with it. It is always safer to attempt an expedition into rough and remote country with another rig (3 is a good number). Smaller tires mean that there will be obstacles that your truck cannot tackle unaided. Most of this can be overcome with a winch, some rigging, a good jack and some bridging ladders (I would recommend these, from discount ramps). If there are deep water crossings, I would recommend a snorkel, and with ARB lockers, it would be a good idea to plumb the air compressor intake into your snorkel, as well as your front and rear differential breathers. A cargo separator and stowage system of some kind would be a good idea as well, because having stuff move around the truck in transit is asking for trouble.

Pack heavy items low, and bulky items high. If you have to put anything up on the roof, it should be bulky rather then heavy.

I try not to toot my own horn, but my truck build has most of the modifications that you would want for this type of travel. Armor, relatively close to factory specs, some lift, and upgraded systems. My sig line contains a link to my build thread.

We takled a trail with some of the terrain you described on a recent trip in NW Arkansas. Here is the link.

Check out Vision X LED bars before you drop the cash on Hellas. They have a much much lower current draw and comparable light output.

Browse, learn, ask questions, then build.

definitely, im undergoing the learning phase, Very good tips. I will be looking into all of these things with what you said in mind. thanks
I am comfortable with all those things that I will need to mod. Although, from the vehicles ive seen go up these mountains, the vast majority of them have larger tires and larger lifts. For the most part 33s should be fine, but there are ledges or an assortment of larger boulders that I will need to pass. And they get worse every year, with erosion and run off, its as if they grow bigger year by year. These are unmaintained roads that only serious off road vehicles can access. The more larger Lift/Tires gets to go to more remote areas.
But then as you say the farther you go, the more risk you have breaking the parts, its a balancing act i feel. I will have to find the medium based on all risks/factors... will be tricky but i intend on finding a very well balanced set up for the terrain here.

I just learned that I can customize the cv joints and diffs on "IFS" vehicles.. i dno what IFS means, I keep reading that on google. IFS vs Straight Axel, What is the difference?? anyone?
EDIT: just found a good article on this:
Independant front suspension VS Solid front axel
http://detr6oit.50megs.com/ifs1.html
As of right now I am leaning to a solid front axel, (if that is possible)

Is it possible to customize the 3rd gen 4runner? or is there some sort of obstacle disabling the customizing of these parts?
I am willing to rebuild parts or reinforce them,
the purpose in this rig is mainly to get out there.
So if i am going to spend a good amount of money on, I can justify spending more to achieve my purpose. If it turns out that rebuilding parts and investing some more money to achieve that purpose, then i will look seriously into building this "dream rig"

I saw your build thread earlier, very cool stuff. And seeing the expedition pics, just excited me to get on with this project even more, very inspiring. :frog:

 

[KokaneeRanger]

Well its nice to see what my truck would look like with a rack and winch bumper on it. When I first read your post I was immediately interested because I am slowly building my own expedition vehicle. When I scrolled down and saw that you had photoshopped MY picture with MY truck I was quite surprised. I am flattered that you chose my pic to "modify". I am currently waiting on a Shrockworks bumper (and already have the winch) to install later on in Feb. and will be sure to post pics when it is finished. I WILL say that the Sonoran Steel 1.2 suspension set up I have works flawlessly so far for the wheeling I do. I have a CBI rear bumper with a tire swing out, 60" extreme high lift, and gas can carrier installed and the added weight seemed to smooth out the rear suspension. You should go to http://www.sierraexpeditions.com and check out what they have for some of the "list" of things you describe. Will and his employees are passionate about 4wheeling and have a great knowledge of what works and what doesn't. Feel free to PM me if you would like to discuss more in detail, otherwise, do what most of us do and visit different forum sites, including this awesome site, with questions and gain some knowledge and ideas of what to do with your future purchase. Good luck and I look foward to seeing your progress!

That was your truck? Lol to that...
I did a google image search and found that...
Its a very nice truck. I saw it as a perfect platform to add the things I wanted, Funny you say shrockworks as the one I put on there is shrockworks aswell. I bet My truck will look exactly like yours as I build it up. You are a few phases ahead of me. and yes definitely we will keep in touch as we hit obstacles during these rig projects, since our purposes are aligned.
I am actually looking forward to building a larger majority of it on my own. I have mechanic friends who would love to come over for a beer and help out...

 

[KokaneeRanger]

New terrain pics

Edited my post and fixed the pictures, they now show up.
Please check them out on page 2

Just used PHOTOBUCKET instead of imageshack to post the terrain pics of where I plan on taking the rig.

 

[Nelsonmd]

Edited my post and fixed the pictures, they now show up.
Please check them out on page 2

Just used PHOTOBUCKET instead of imageshack to post the terrain pics of where I plan on taking the rig.

Yay, now I can see them. Thanks.

 

[ironhippy]

like it's been mentioned, you are looking at a LOT of mods. If you aren't married to a 4runner, a Land Cruiser may be a better platform to build from. They are frequently for sale in BC

British Columbia land cruiser cars for sale, buy used autos - Kijiji British Columbia

And there is a fair amount for sale in Alberta:

Alberta land cruiser cars for sale, buy used autos - Kijiji Alberta

 

[Mr. Leary]

like it's been mentioned, you are looking at a LOT of mods. If you aren't married to a 4runner, a Land Cruiser may be a better platform to build from. They are frequently for sale in BC

British Columbia land cruiser cars for sale, buy used autos - Kijiji British Columbia

And there is a fair amount for sale in Alberta:

Alberta land cruiser cars for sale, buy used autos - Kijiji Alberta

like it's been mentioned, you are looking at a LOT of mods. If you aren't married to a 4runner, a Land Cruiser may be a better platform to build from. They are frequently for sale in BC

x2. A solid axle would be a more suitable choice for the terrain you wish to traverse, although I still maintain that 33" tires would complete all the trails pictured above (I can see them now). For that bouldered hill climb, a pair of bridging ladders would make it relatively easy. With the steep hill climbs you mentioned, you would be better off in a long wheelbased rig, and for the rocky stuff in those Jeep pics, you will never do better then a SWB Wrangler. It will be a compromise. A LC will be less of a compromise in strength, but will be larger and can get unweildy on tight trails.

If you are really after making the 4Runner a rig that is large and in charge, you will be in solid axle swap (SAS) territory. A good choice for a front axle is a Dana 44 out of a Jeep Wagoneer (driver side drop). This route involves extensive fabrication and will be very expensive... you would be better off buying a rig that already has a solid front axle, such as a pre-1998 Land Cruiser or a Jeep Wrangler. I believe the best choice for a rig to suit your purposes will be a 4 door Jeep Wrangler Rubicon with 35" tires. It isn't overly large, but has enough cargo area to carry all the gear you will need for a week long trip. It also has a long enough wheelbase to complete the hill climbs. Last, and probably most important, it will require minimal mechanical knowledge to modify. It already has F/R lockers, strong axles, and there are bolt on accessories for anything you can imagine.

Anyways, good luck with your build. The 4Runner will do it, but if you go bigger then 34" tires, you will be breaking stuff sooner or later.

EDIT: Also keep in mind when building the truck that every drivetrain component you beef up only creates a weak link somewhere else. For example, getting bomb proof CV axles will put you at risk of blowing up a front diff. 4Runner hubs are already very strong, and the CVs are quite strong as far as IFS trucks go, but the 7.5 is not a strong differential. Closer to stock reduces strain and keeps components running within design specifications. You would not try to tow a large gooseneck trailer with a Honda Civic. You should not try to run huge tires on locked axles when the truck was not designed for it.

 

[topdown4runner]

After looking at the pics ( finally ) I don't see anything one of the more capable trucks like Mr. Leary's couldn't handle with ease.

Hell, I'd try everything but the river crossing in my '87 with 32's and only a rear locker since I don't have a snorkle.
When my '99 has the armor completed, I'd try those trails.
Looks like fun

 

[KokaneeRanger]

like it's been mentioned, you are looking at a LOT of mods. If you aren't married to a 4runner, a Land Cruiser may be a better platform to build from. They are frequently for sale in BC

British Columbia land cruiser cars for sale, buy used autos - Kijiji British Columbia

And there is a fair amount for sale in Alberta:

Alberta land cruiser cars for sale, buy used autos - Kijiji Alberta

Good idea, I actually looked into land cruisers since you mentioned them. But I just am so passionately connected to the 4runner. Always have been, and always wanted one....

 

[KokaneeRanger]

x2. A solid axle would be a more suitable choice for the terrain you wish to traverse, although I still maintain that 33" tires would complete all the trails pictured above (I can see them now). For that bouldered hill climb, a pair of bridging ladders would make it relatively easy. With the steep hill climbs you mentioned, you would be better off in a long wheelbased rig, and for the rocky stuff in those Jeep pics, you will never do better then a SWB Wrangler. It will be a compromise. A LC will be less of a compromise in strength, but will be larger and can get unweildy on tight trails.

If you are really after making the 4Runner a rig that is large and in charge, you will be in solid axle swap (SAS) territory. A good choice for a front axle is a Dana 44 out of a Jeep Wagoneer (driver side drop). This route involves extensive fabrication and will be very expensive... you would be better off buying a rig that already has a solid front axle, such as a pre-1999 Land Cruiser or a Jeep Wrangler. I believe the best choice for a rig to suit your purposes will be a 4 door Jeep Wrangler Rubicon with 35" tires. It isn't overly large, but has enough cargo area to carry all the gear you will need for a week long trip. It also has a long enough wheelbase to complete the hill climbs. Last, and probably most important, it will require minimal mechanical knowledge to modify. It already has F/R lockers, strong axles, and there are bolt on accessories for anything you can imagine.

Anyways, good luck with your build. The 4Runner will do it, but if you go bigger then 34" tires, you will be breaking stuff sooner or later.

EDIT: Also keep in mind when building the truck that every drivetrain component you beef up only creates a weak link somewhere else. For example, getting bomb proof CV axles will put you at risk of blowing up a front diff. 4Runner hubs are already very strong, and the CVs are quite strong as far as IFS trucks go, but the 7.5 is not a strong differential. Closer to stock reduces strain and keeps components running within design specifications. You would not try to tow a large gooseneck trailer with a Honda Civic. You should not try to run huge tires on locked axles when the truck was not designed for it.

Ic ic.. hmmm very tough decision.
Based on my passion for a 4runner I think I will stick to my choice and bite the bullet and realize I will have to Mod more things on a 4 runner to get it up to par for my application.
I drive a 18 wheeler semi truck for a living and I am used to driving larger vehicles (gmc suburban 2500). I simply like larger vehicles, but I understand for the trail you must go more compact to get into those smaller areas.
There are plenty wide enough trails for a 4runner up here in BC, so I wont run out of trails. I would also do trips to MOAB and MOHAVE in the future with the necessary mods for the desert of course.
Based on my love for 4runners, I will stick to them.

and you say how there is always a weak link in the drivetrain when you go with such big tires... that is something I will have to get used to, that I will be replacing parts and heavy customization/fabrication..

After the past few days and posting this thread up, and reading opinions on here I have a Good Idea of what I want now and what will be ideal for me.
Since I will use this vehicle on the highway sometimes as a pleasure recreation vehicle (not as daily driver).. I will include some parts and leave some out for the "multipurpose" use i intend on using it for.

All I can say is, I cant Bloody wait to get on this. I will have to wait sometime until later this year to start this project. Ill include tons of descriptions and pictures as it goes along and I am sure I will be asking around here for opinions as obstacles and problems are infront of me...

Thanks for all the help!