Newbie: 1997, 4 runner, rusted out

[werminghausen]

I bought a 4 runner for cheap to bring it back to the streets in Massachusetts.
The frame is rusted out badly and I bought flat steel for welding. Especially the middle parts underneath the driver doors are so rusted out that there is not much steel left
This is not a problem I think.

The worst part for me are the body panels, underside...both rocker panels need to be replaced... do you know a good source for rocker panel/sheetmetal?

Then timing chain... need to install a new timing belt.... what is best?
belt set including water pump?
Do you have a manual for this job?
(I am a hobby mechanic and can do this job).

What is essential/important to look for before I drive the car except for the fluids? Engine seems to run well.

Martin

 

[werminghausen]

here are a few pictures of the rusted 4 runner...frame and body.

I think I can fix this with a lot of work although it is tough because any bolts I want to open are rusted out too and break off. (What kind of steel is Toyota using?)... but the other question is: what do you recommend to do on the engine transmission side in order to survive the first winter?
Best, Martin

 

[werminghausen]

Well, these holes are fixed by now...
Martin

 

[MVP]

Got any photos from the 'fix it' process?

I would love to see what you did along the way....

op2:

 

[werminghausen]

See if I can find pictures

Phase 1 Frame: First is pounding with a hammer on the frame.... what stays is good what falls off..well and what is bent is all bad. of course you need to find the right force to tell if frame is good or bad.
In parts there was just nothing left underneath (I was wondering why this frame was not bent or destroyed. Seriously there came 25 pounds of rust scale out of the frame and I welded around 30+ pounds of steel in...mostly flat steel
1/4" thick. Frame is strong now... I hope. before welding I was using phosphoric acid on all parts.... to stabilize the rust and get a good basis for
rustoleum.

Phase 2 body/Rocker panels.. and rear end of truck. There were more hold in than solid material. You can tell from the pictures... in the end there were double the size holes in the body. I welded each of the holes with fresh sheet metal. most complicated were the ends of rocker panels /wheel wells front and back. There was just nothing left.

In the end the car is fine now.

I had massive idle problems...engine was idling at 1500-1800 and with a well cleaned idle air valve I brought it down to 700 now... much better and less fuel.
I need to do the rear u joint now...car is like an airplane at 60mph... last u joint is toast. I don't know how to press the u joint out...hammer?

Best, Martin

Got any photos from the 'fix it' process?

I would love to see what you did along the way....

op2:

 

[MVP]

Thanks for posting.

We don't have many with rust like that here in Arizona (only those that migrate from other places), but it reinforces my need to get a welder.

Yes, it is a need, not a want (practicing for when I tell my wife) :amen:

 

[werminghausen]

I have a MIG welder and without it I'd have been lost many many times.
The weird thing with my Toyota is that each and every bolt I touch it snapping because the thread is rusted to the nut and the nut s welded the body...
That is a bad system... I only deal with Mercedes and they never use this bolt system..... except for studs (exhaust manifold etc). If a bolt snaps the nut is lose and easy to exchange.

Martin

 

[99 Problems]

I have a similar looking rear rocker panel (near the wheel well) except the previous owner used bondo to hide it.

My fault for not checking. Would like to get it fixed except I have no welding experience. Could you send some close up's of that area? What was your procedure?

Thanks!

 

[Dropzone]

OP hasn't been around in 2 yearslayball: