rustED's 87' 4runner Expedition Build

[JBurt]

That sucks. I'm really sorry man. I'm glad you sound like you're okay.

 

[rustED_]

That sucks. I'm really sorry man. I'm glad you sound like you're okay.

Thanks. Yeah I was ok, didn't even really feel the impact at all (I was probably doing around 50 mph when I hit the deer).

I found a guy locally on Craigslist that has over 40 toyota 4x4 pickups and 4 runners that he is parting out, so I'm hoping once I get some extra money that I can source most of the parts from him. We don't have any local wrecking yards around here, plus it's getting hard to even find that old of toyotas in them anymore.

Future upgrades after front sheetmetal repair will include home built front bumper with grille guard, (I'm thinking something out of Mad Max) and a headlight upgrade. Anyone have a recommendation on the what headlights I should consider? Thanks!

 

[JBurt]

If you look at [MENTION=25058]ChildrenOfBodom[/MENTION] turbo 4runner thread I think he upgraded to a headlight housing with replaceable bulbs.

 

[rustED_]

If you look at [MENTION=25058]ChildrenOfBodom[/MENTION] turbo 4runner thread I think he upgraded to a headlight housing with replaceable bulbs.

Thanks, I'll have to check out his thread!

 

[Thefishguy77]

I'm glad your ok. We don't have many deer down by me. But the elk are everywhere. Not sure I can build an elk resistant bumper. After seeing this makes me want to upgrade my brakes.


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[rustED_]

I'm glad your ok. We don't have many deer down by me. But the elk are everywhere. Not sure I can build an elk resistant bumper. After seeing this makes me want to upgrade my brakes.


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Thanks. I'm thinking it's time for a brake upgrade too, I'd like to do a disc conversion on the rear, still doing some research on it as I am wanting to retain my emergency brake.

 

[Dropzone]

a more expensive option but I had the Truck Lite LED's in my Trekker, they were awesome. If I could have found a grill and housing from a 90-1 4Runner or early 3rd gen truck they would have been transplanted into my 94 4Runner. Sold them a year or so ago and a friend has been running them in his 3.4 converted 88 4Runner.
Great clear pattern, low amp draw.
about 2 years into them being in the Trekker I had one end up with moisture in it causing it to flicker. The 3 year warranty came into play and Truck-Lite replaced both lights.
disadvantage is they don't have enough heat to melt heavy snow on the lenses, about $400'ish for a pair

Here is a review for them posted on YT
Truck-Lite 5x7 LED headlight review - YotaTech Forums

here is a good comparison thread on several options from Pirate
Pirate4x4.Com - The largest off roading and 4x4 website in the world.

If you want a nice more reasonably priced option the Hella E-code H4 are a great option. I ran those in my old 84 and transplanted them to my 97 Taco.
Hella 003427 861 H4 Conv H6054 SEALED Beam to 72206 H4 Halogen 200mm Euro Lense | eBay
I ran these when I was stationed in Alaska with 130w high beams (a bit illegal) but they sure threw light down the road and I saw moose with more than enough time to stop

 

[rustED_]

Well did a little "body work" today.


^^^Body work tools of choice






^^^"before" pics of the damage are above....."after" pics are below










^^^I Frankenstein'D some temporary repairs out of parts I had laying around. Drivers side headlight bucket is modified off of a 79' ford F250. Its a mounted a little lower than stock, but works for now. The turn signal is old LED I had kicking around. Remounted my old chrome bumper after massaging some of the dents out of it with the 3lb sledge. Also had to replace the belt as it was twisted and frayed from rubbing against the fan shoud and driving it home like that. Luckily I had a spare belt. Total cost of Frankenstein repairs...$0. The 4runner will be resuming it's dd status tomorrow. I'll start collecting parts for real repair ASAP.

 

[rustED_]

a more expensive option but I had the Truck Lite LED's in my Trekker, they were awesome. If I could have found a grill and housing from a 90-1 4Runner or early 3rd gen truck they would have been transplanted into my 94 4Runner. Sold them a year or so ago and a friend has been running them in his 3.4 converted 88 4Runner.
Great clear pattern, low amp draw.
about 2 years into them being in the Trekker I had one end up with moisture in it causing it to flicker. The 3 year warranty came into play and Truck-Lite replaced both lights.
disadvantage is they don't have enough heat to melt heavy snow on the lenses, about $400'ish for a pair

Here is a review for them posted on YT
Truck-Lite 5x7 LED headlight review - YotaTech Forums

here is a good comparison thread on several options from Pirate
Pirate4x4.Com - The largest off roading and 4x4 website in the world.

If you want a nice more reasonably priced option the Hella E-code H4 are a great option. I ran those in my old 84 and transplanted them to my 97 Taco.
Hella 003427 861 H4 Conv H6054 SEALED Beam to 72206 H4 Halogen 200mm Euro Lense | eBay
I ran these when I was stationed in Alaska with 130w high beams (a bit illegal) but they sure threw light down the road and I saw moose with more than enough time to stop

Thanks for the links to the headlights Robb, I'll be checking those out for sure!

 

[Thefishguy77]

Looks like you just proved the theory that hammers do solve problems. Good down and dirty bodywork.


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[rustED_]

I haven't updated this thread in awhile. I haven't done much to the 4 runner, just been driving it. Tax return came in awhile back, I was going to use some money to fix the front end replace the hood, fender grille etc, but ended up buying some tools instead. I bought a like new 20 ton hydraulic shop press off craigslist, also bought a Bead roller from Woodward Fab.

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^^^Made a few modifications to the press. Added some uhmw guides to take some of the side to side play out of the press. I also built a press brake so I can make some 90° bends.






^^^Reinforced the bead roller frame with some 2x2" square tubing to keep it from flexing and built a stand. The original handle sucks, so modified a tire iron for a handle, works much better. I plan to motorize the beadroller and add a forward reverse foot pedal/switch.

 

[rustED_]

^^^getting some practice in, made a tailgate panel and a couple different styles of rear cargo panel doors. I"m learning as I go, been watching alot of YouTube videos too. I need to build a table to support the sheet metal as I use the bead roller, the weight of the piece hanging over the edge unsupported on the tailgate panel contributed to the panel warping.

 

[wallytoo]

nice looking panels. you might find some buyers, too.

 

[rustED_]

nice looking panels. you might find some buyers, too.

thanks, I'm going to be working on a door panel soon, already have it cut out. It's been good practice, I hope to get some aluminum sheeting eventually, just figured I'd practice on some cheaper steel sheet metal first before attempting to use some more expensive aluminum.

 

[rustED_]

opened a can of worms today...






A lot of rust in the structure behind the quarter panel that needs addressed before I can start repairing the quarter panel...

 

[rustED_]

Worked on a couple more practice panels, used 20 gauge this time, it was a lot easier to work with.


^^^this was my first attempt at doing lettering

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I might try a faint diamond checker back ground on the second one..what do you guys think try it or leave as is?

 

[rustED_]

^^^I'm kind of surprised to still see pics up on here from my last post, I figured photosuckit would have held them for ransom by now, lol.

Just thought I'd post a few pics of what I've been up to lately.
I got a better beadrolling machine to replace my other manual handcrank model.



^^^Built a table for the new beadroller.

Here's my first attempt at door panels, did these on my old machine.

These next door panels are the ones I am currently working on, the center circle will have a guys custom logo in it.

 

[rustED_]

Here's some of my first tailgate panels I did. I designed these in 3 peices, the center cover bolts the main 2 halves together. It's made from 18 gauge sheet metal and is really sturdy. By making them in this way I'm able to keep the shipping cost down.










^^^In this pic you can kind of see how the 2 large halves fit together with a lap joint, then the center cover bolts them together.

This one is a custom logo I did for a customer.

 

[rustED_]

Here's some rear cargo area access doors I did:








^^^working on designing some rear cargo area side panels, might make them in multiple smaller sections instead of one large piece to make shipping easier and more affordable.

 

[JBurt]

That's literally the coolest stuff I've seen all day!

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