My 1997 SR5 build and repair thread

[19963.4lsr5]

Good plan. Very common for the bottom to be rotted out in the arch. Making progress

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I set up my mig today and have gas. I have the .060 wire for sheet metal in it currently.


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[19963.4lsr5]

So the sleeve is in and it’s as close as I can get it. It’s tack welded in place on the outside. I went to do the inside of the frame sleeve and it was too awkward. I need to get it up in the air much higher.

Tomorrow I’ll get it up higher and tack it in place so I can remove all the clamps and then start burning it in.

The primer I used let’s me burn through it so I’m happy I didn’t have to have bare metal at the joint.

I’ve been doing the Z welding pattern to make sure I’m hitting both sides for penetration.


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[brillo_76]

So the sleeve is in and it’s as close as I can get it. It’s tack welded in place on the outside. I went to do the inside of the frame sleeve and it was too awkward. I need to get it up in the air much higher.

Tomorrow I’ll get it up higher and tack it in place so I can remove all the clamps and then start burning it in.

The primer I used let’s me burn through it so I’m happy I didn’t have to have bare metal at the joint.

I’ve been doing the Z welding pattern to make sure I’m hitting both sides for penetration.


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Looks great. You get that LCA where you wanted it?

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[19963.4lsr5]

Looks great. You get that LCA where you wanted it?

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Front to back is perfect. Height of the hole is off 1/8”. I’m using a product called “Steel It”


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[JBurt]

Well done! I wish we all had lifts. It would make life so much easier.

 

[bushwhackrunner]

nice build!

 

[brillo_76]

Front to back is perfect. Height of the hole is off 1/8”. I’m using a product called “Steel It”


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1/8 because of rotted off bottom?

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[19963.4lsr5]

1/8 because of rotted off bottom?

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No, the sleeve isn’t perfect. If I put the hole 15” off the floor the front of the sleeve has a 1/4” gap. Putting the sleeve tight against the frame drops the lower control arm hole 1/8”.


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[brillo_76]

No, the sleeve isn’t perfect. If I put the hole 15” off the floor the front of the sleeve has a 1/4” gap. Putting the sleeve tight against the frame drops the lower control arm hole 1/8”.


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Interesting

 

[19963.4lsr5]

So I did some mig setup and practice welds and put the arse of the 4Runner higher in the air.

Today I did yard work and bought a welding jacket. 20 years ago it didn’t bother me. Now that splatter hitting my stomach is annoying.

Tomorrow I continue welding.


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[19963.4lsr5]

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[19963.4lsr5]

The sleeve is welded in place and primed. I’ll do more work tomorrow.

I need to paint the frame, put new rear sway bar links on and replace the seals in the gas tank as well as the suction strainer.

I’m thinking next off stretch I’ll be driving it.


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[19963.4lsr5]

The frame is painted, new rear swaybar links. Dealing with the gas tank currently. Since the tank is on the floor I may as well replace the seals to eliminate the dreaded EVAP leak codes.

I start my work stretch tomorrow. So next time I’ll be able to work on it will be next Wednesday. Not much left to do. Just the tank sending unit gasket and start putting it together.


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[brillo_76]

Tank wasnt too rusted. Mostly they look alot worse then that..

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[19963.4lsr5]

Today between a haircut I finished the gas tank. I’ll install it tomorrow.

What is this part of the sending unit?

Is it the low level switch? It has its own wire.


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[phattyduck]

Is it the low level switch? It has its own wire.

Yeah, that's how the '96-'98 low fuel light works. It is a thermistor that goes low resistance when it comes out of the fuel which lights the low fuel light. That gets you the cool slow-on-and-off of that low fuel light...

-Charlie

 

[19963.4lsr5]

So it’s back on the road.

Best part is, the steering wheel is still as strait ahead as I remember it before.

I need to install the tank skid yet.


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[JBurt]

That's got to feel pretty good! Congratulations.

 

[brillo_76]

Great job.

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[19963.4lsr5]

So my upcoming projects (if you all haven’t been following along) are replacing the 53mm Alt pulley with a 50mm one to speed up the Alt at idle to try and correct the automatics problem with being in gear idling at 600rpm and the battery discharging because the Alt can only push around 40a at 600rpm

Another project is installing a wiring harness for my headlights I got from Amazon.


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