96 4Runner Build - High Mileage

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Downeys4Runner

New member
Hey guys, This is the start of my build thread. I had one started but it was a fail.

About me: I'm 16 and bought this truck when I was contacted from a wanted ad on kijiji. I work part time and don't make enough money to satisfy my want to mod! My brother has an 03 Tacoma so he helps a lot with it. I have a weird situation where I don't have my G2 license so I couldn't drive it. It gives me time to work on it. Only a little over a month till it on the road. :banana: I'm in the stage where i'm getting it satisfied. Hopefully there isn't a lot to do and I can get Modding!

The Truck: So i bought it kind of impulse. I wanted a 4Runner for a really really long time. The guy contacted me and it was mine in 2 days. Over 300 thousand kms but the engine is in good condition. Has an e-Locker that causes headaches. Had lots of surface rust and the rockers had holes in them. I harnessed my inner body worker and fixed those up.

TIME 4 SOME PICTURES



Here you can see the rust on the hood and above the windshield! OHH NO



If you look at the very back of the rocker you can see the holes! Same on the other side!



Clean engine with timing belt and other maintenance done regularly.

BODY WORK:

So there was lots of body work to be done, not a lot of money in the bank and a lot of time. So I decided to tackle it myself. I started by picking up supplies.

Get something to get the paint off, I used this thing and it was a life saver! Isn't to harsh on the metal but gets the paint off. And lasts surprisingly long!



Then I got Bondo, get a big container. For a 1$ more its worth it, and you'll use more than expected. It comes with hardener. Get a bunch of spreaders and trays to mix on. Here are the pics...



SMALL SECTIONS IS BEST! Dries quite fast...



Sand with 80 Grit, then go to 120 to feather edges, finally 800 before paint and 1000-2000 for after paint if desired. I am wrapping the truck so I'm not worrying about paint to much. Just a primer.



1st coat on the hood



Close to the finish



The Start of above the windshield! It wasn't very fun!



Now the beautiful rockers and fender, here is the Driver side rocker after the sanding/grinding and the drivers side fender.





I used fiberglass to fill the holes! Work quite well! :biggrin1: Was a tedious process but worked. I then filled with bondo till smooth. This was very tough cause gravity hates me. It turned out good. I didn't worry to much about the smoothness because you cant really see it.

Passenger side, about the 2nd coat



Driver side, 1st coat. Looks horrible but with a power sander and sometime it turns out good.



Here is the hole in the driver side wheel well...



And this is the driver side fender... Remember there wasn't any metal in that hole! Fiberglass is an amazing thing.



I'll post more later... I think I have picture of the finished project somewhere. Or ill take some. Any questions let me know.
 
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Black Grille!

I got bored from a bunch of Bondo and fiberglass... So I started a small project. The grille of the truck was peeling real bad so i decided to peel it all off. It sucked... A LOT! cut my hands a s*** load and it took a long time. But it was the only way. After that I sanded it really good.

Here is the grille half peeled...



And the final product. Not great but not bad at all...



 
Looking good..... especially for a 16 year old. Nice to see someone your age tackling projects like this.
 
I am trying to paint a dent/corrosion in my car. So I am going to follow your steps
1) clean the metal and apply bondo right on the metal
2) sand it with 80, then 120 and finally 800
3) Then base paint?
4) Finally clear coat?

Am I missing anything?
Thanks
 
nissanh said:
I am trying to paint a dent/corrosion in my car. So I am going to follow your steps
1) clean the metal and apply bondo right on the metal
2) sand it with 80, then 120 and finally 800
3) Then base paint?
4) Finally clear coat?

Am I missing anything?
Thanks
Click to expand...

What you will want to do is make sure the metal is clean before the bondo. Don't rush anything. Do all your prep make sure you don't miss anything then mix up your bondo. Keep thing coats. Easier to add more than take a lot off. I think you'll do great. Be patient it's not the most fun but it will make a huge difference.
 
Downeys4Runner said:
What you will want to do is make sure the metal is clean before the bondo. Don't rush anything. Do all your prep make sure you don't miss anything then mix up your bondo. Keep thing coats. Easier to add more than take a lot off. I think you'll do great. Be patient it's not the most fun but it will make a huge difference.
Click to expand...

OK, Thanks
So I follow the series correct?
 
Lift kit options

Okay so here are my options, I have been scrambling around toyotec for a bit looking for deals ect and trying different combinations an I think I found the one.

1st Option:

My brother has a sick Tacoma and it was the inspiration to the 4Runner :focus: but he is wanting to do a Mid-Travel Suspension Upgrade to his front end. He has an existing 3" Bilstein lift on the front with coils and said when he gets the Mid- Travel I can have it, for a price of course. So I can buy the rear so I was thinking ToyTec Superflex Rear Coils and Rear Bilstein Shocks. I forgot the exact price but it comes to around $450ish. So I can do that with my brothers front which comes to around $650-$750. Not bad but I have to wait until he's got lots of money to blow.

2nd Option:

I'm pretty sure I found the best set up on toyotec, don't know if I'm missing anything. So its 3" Lift Kit with front and rear OME coils. This gives you front and rear coils and I took away the spacer and added a diff-drop. Then add the Front Bilstein Height adjustable 5100 shocks and Rear Bilstein Shocks. And voila, $778.97 plus shipping to Michigan (got to pick them up) so around $820ish.

1st priority would be to get my truck on the road but the mod bug got me bad... real bad! :dance: Let me know what you think works best! Thanks guys
 
Lookin' good bud! I respect you for getting dirty and fixing your truck, instead of trying to find another 4runner. Also, I don't know how your able to work on it all the time and not drive it! It will all pay off when you get to take it out. Bondo job looks good!

Are you thinking about painting the entire truck matte black? Or are you just approaching those cancer spots one at a time?
 
nice work! hows the frame holding up? Looks like you might want to treat any rust areas you find on the frame while you're in there..
 
Brian757 said:
Are you thinking about painting the entire truck matte black? Or are you just approaching those cancer spots one at a time?
Click to expand...

Thanks man, I'm doing tye spots one at a time... My dad is a graphic designer and he wraps vehicles. I'm undecided on the colour. Black is an option with matte accents but that's so normal. I was thinking olive or army green. Something different
 
audiness said:
nice work! hows the frame holding up? Looks like you might want to treat any rust areas you find on the frame while you're in there..
Click to expand...

Ya! I agree... If it passes safty I won't worry about it for a bit but I may have to do something about it. What do you recommend I do? If it doesn't pass am I able to weld on supports? I will eventually paint it up and fix some of it.
 
Awesome work.


Spraying it with Rust Check will at least protect it from more damage. (After any painting will save you a lot of grief, I'm sure). Trying to reach perfection under there will just make you insane. Fixing up the visible areas with a grinder and some rust paint will make you ride look nicer. Area to pay attention to--behind the gas tank (seems to be a bad area for Runners).
 
Maritimer said:
Awesome work.


Spraying it with Rust Check will at least protect it from more damage. (After any painting will save you a lot of grief, I'm sure). Trying to reach perfection under there will just make you insane. Fixing up the visible areas with a grinder and some rust paint will make you ride look nicer. Area to pay attention to--behind the gas tank (seems to be a bad area for Runners).
Click to expand...

Thanks man, I agree it doesn't look very good. I just hope there is no major structural work needed. Near the back bumper its pretty bad! If there is an issue with the structure am I able to just grind it down then weld on supports? Like reinforcements?
 
Downeys4Runner said:
Thanks man, I agree it doesn't look very good. I just hope there is no major structural work needed. Near the back bumper its pretty bad! If there is an issue with the structure am I able to just grind it down then weld on supports? Like reinforcements?
Click to expand...

Not sure on the process to fix any weak spots on the frame. If you know how to weld, I'd think that tackling any obvious spot before an inspection would make it go smoother--just make sure you find out about the rules first.

I wasn't suggesting your Runner looks bad--I was just speaking from experience. When I took my running boards off my truck looked kind of ugly, so I spent some time with an angle grinder and some rustoleum. I wish I had more time, could lift the body, and could do the job with POR15, but I figure it's good enough for now. We should just be thankful these machines still drive, that we aren't in broken down American rides--I figure my Runner is just getting broken in at 244000.

Rear bumper area--definite weak spot on these--especially drivers side with not enough heat from the exhaust to keep it dry, and all the extra road salt from the center of the road, and the hiding spot behind the gas tank.
 
Great work at 16! I have a black '00. The only place that seemed to rust was the rear chrome bumper. I'm pretty sure we've driven through sand and failed to rinse it a time or two. When we installed the new aftermarket bumper I put several coats of undercoat on it. I PM'd you.
 
Update

So I got the list for my safety back. There is some tougher things but its easy to work through. The frame patch is really small and the guy said he would just leave it and he will let it pass. I have a problem with the tires in that I just need a front right one! I just want a lift and 33" so im not gonna buy just one tire. I'm gonna get my brothers winter tires throw em on, it will pass then wait till I get a lift.

Here is the list:



I also started fixing the rusty looking frame. With a wire wheel and power tools it took about 30 min and it looked like new from a wee distance. :rockon: It totally changed the look. Don't mid the skid plate from the gas tank that s*** is coming off once I get it to school where they have lifts! Its a ***** with out one. It looks way better than it did with an orange rust look!

Picture of the frame after paint (sorry was getting dark):



Update on the body work! looks great but is starting to f***ing bubble. I don't care cause this thing wont last to long but I need to cover it up. I have those gay SR5 skinny flares that i'm gonna put back on but if someone has the bigger black SR5 ones I will pay!

Evan
 
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