Hoist for 1st Gen Topper

[illzoni]

Updated April 22, 2014...
A user pointed out I'd referenced PDF plans but not uploaded them. They're now included.
And I've edited the OP to include the Lowe's receipt with PNs.
HTH,
Jon

The removable top on the 1st Gen 4Runner is one of the primary reasons I wanted the truck. I quickly realized after buying mine that ease of removal and re-installation would be key to maximizing my enjoyment of the 4Runner.

Initially I used ropes using ratcheting pulleys, but that involved many adjustments to each corner as I raised or lowered the top. It was a workable solution for the time being, but not the desired end state.

The attached drawing (PDF) gives a rough illustration of what I wanted to do.
I bought a manual crank winch at Harbor Freight: 1000 Lb. Capacity Hand Winch

I got everything else from Home Depot and/or Lowes:
These are the pulleys I used: Shop Covert 2" Heavy-Duty Wall/Ceiling Mount Pulley at Lowes.com
I'm not sure if this is the exact shackle I used: Shop Blue Hawk 5/16" Chain Anchor Shackle at Lowes.com
I used thimbles at each cable end to keep the cable from kinking or folding: Wire Rope Thimble and Clamps-7310-6 at The Home Depot (I bought similar without the clamps.)
To secure the cable I bought ferrules similar to this: 1/8 in. Aluminum Ferrule and Stop Set-7332-24 at The Home Depot
This is an example of the swaging tool I used to crimp the ferrules: Amazon.com: Swaging Tool, 18": Home Improvement

Using the 2x4s (and 2x8 and 2x12s) allowed me to firmly mount them to wall studs or ceiling joists and then locate the pulleys on the boards exactly where I wanted them. Some of the photos may show the winch attached to a 2x6. However, the torque on it--and possible not the best mounting to the studs--made it necessary to upgrade to a 2x12 to ensure stability.

I haven't yet resolved attaching the top to the cable ends to my own satisfaction. The tie-down straps are working okay, lending some adjustability to get it level, but I'm not entirely please with the attachment point on the top. When I figure out something better I'll share it.

I can now remove and hang or lower and re-install the top, and install my bikini, in about 20 minutes...

Removal:
Parked in driveway, remove all bolts (I never use them all) with cordless drill.
With straps and cables hanging down, back in between them.
Lift each corner manually and insert a 2x2 spacer between the top and truck.
Left each corner a bit more and attach the end of the tie-down.
Put my camping sleeping foam on top of the top, then crank it up to the ceiling.

Re-installation is pretty much just reversal of removal.

 

[turboSR5]

Cleanest, most functinal DIY hard top lift that I have ever seen.

 

[illzoni]

I was cleaning out my clipboard and found the Lowes receipt for most of the parts I used, including the swaging tool. The PNs may be handy for anyone looking to do similar.

 

[Awz]

Looks good. I built a similar rig this summer, but yours looks a little more user friendly. Mine is a bit of a pain, but it works.

 

[SEoperator77]

It looks excellent. I would have to modify the design a bit to make it work.

 

[SEoperator77]

bump

 

[illzoni]

Now the question...

Do I remove it and take it with me when I move?

 

[mbonny]

hey, great job

I like this pulley system you've got, great job.

I'll be putting one up too. Any modifications that you've made since you posted this?

 

[illzoni]

I like this pulley system you've got, great job.

I'll be putting one up too. Any modifications that you've made since you posted this?

Not yet. I left the 2x4s mounted to my wife's house back in Tucson when we moved to Tennessee in February. I brought all the pulleys, cable, and hoist with me. As we rented before buying, I haven't yet installed it here.

I've never been thrilled with using the tie-down straps to attach the top and make fine adjustments. Here's what I'm thinking...

First, I want something that will allow me to use it for other purposes when not hoisting the T4R top. I want a straight 'bar' that runs across under the top so it's actually only sitting on the bar rather than stressing the holes I've been hooking to. To make it easier to deal with the bars and slide them under the top once I have it blocked off the truck with 2x2 stock at each corner, I intend to make each bar out of square tubing. Actually, each bar would be two pieces of square tubing with one having an outside dimension slightly smaller than the inside dimension of the other, allowing the bar to telescope for both adjustability and ease of use.

Secondly I want to eliminate the straps for adjustment. I think I'll use turnbuckles at the end of each cable (like this: National Hardware® 2172BC 3/8X16 Turnbuckle Hook/Eye, Zinc - 3549540 | Tractor Supply Company) that will let me get it perfectly matched to the truck.

We'll see how it goes. I'll update when I do get around to it.

 

[helo-mech]

First, I want something that will allow me to use it for other purposes when not hoisting the T4R top. I want a straight 'bar' that runs across under the top so it's actually only sitting on the bar rather than stressing the holes ..........

I was thinking the same with my home made rack/lift/hoist not sure what to call it. I had just straps, then a 2x4 on the rear and straps in the front and now I have a 2x4 in the front and rear. I feel that it is a lot more stable that way. The rather large cut across my forehead last week was proof that it could take a hit and not fall to the ground.

It also gave the option to use it for stuff when the top isn't in it, but after looking at it I have decided not to use it for anything but the top. I'm a "everything in it's place" kind of guy and I figured I would be scratching my head trying to relocate what was being stored up there every time I wanted to use it for the top. In the end, I just raise it all as high as it will go when it is not in use.

I do like your cable, pulley and crank system though. If I ever get to a point where I'm not trying to spend some money on the 4Runner, I am going to trade out my eye bolts and straps for your setup. Something tells me that might be awhile though.

 

[illzoni]

If I ever get to a point where I'm not trying to spend some money on the 4Runner, I am going to trade out my eye bolts and straps for your setup. Something tells me that might be awhile though.

At the very least turn that near strap around so you can pull down to lift the top!

 

[helo-mech]

At the very least turn that near strap around so you can pull down to lift the top!

Yeah realized that oversight after I raised it. Swapped it over when I brought it down. Much easier.

 

[ChildrenOfBodom]

THIS IS AWESOME! I am so building one of these... haha

 

[SecretSquirrel]

Not yet. I left the 2x4s mounted to my wife's house back in Tucson when we moved to Tennessee in February.

DM I'm guessing? Where'd you work? I was with the 42d ACCS there back in the 90s. They shut down the squadron a few years ago though...

 

[illzoni]

DM I'm guessing? Where'd you work? I was with the 42d ACCS there back in the 90s. They shut down the squadron a few years ago though...

Actually, no.

My Tucson/military dates...
91-94 41ECS;
94-95 355WG/HG;
95-98 Compass Call Evaluation Team (AFOTEC);
98-06 162FW (ANG);
09-12 AATC (tenant at ANG).