SRQ Fabrications Ultra4 4600 3rd Gen Build

[4Running Daily]

After the frame rails were mostly straight, it was time to deal with the core support.

**** sheet metal.

Story time: I bought this 4Runner from a dude in Surprise, knowing it had a rebuilt title already. But that's fine #racetruck, what do I care. Obviously the front end was ****ed from the accident, so I didn't really look too carefully. Plus he told me it had an elocker, and when I got there it didn't. And because there was a tow truck in front of his house already, he wouldn't negotiate. So $2k came and went.

Now that I'm balls deep in this truck, I've discovered that the core support has actually already been replaced once before. So not only am I fixing one accident, I'm actually fixing 2. I'm thinking the first accident that totaled the truck is the one that bent the frame rail. It was fixed cheaply, and then given a rebuilt title before it was smashed again and I bought.

Long story short, **** this thing.


Core support rails looked like this:
Untitled by Connor Rhoades, on Flickr

New core support
Untitled by Connor Rhoades, on Flickr

Had to pull the original out in an attempt to un-**** it.

Untitled by Connor Rhoades, on Flickr

Then cut it
Untitled by Connor Rhoades, on Flickr

Start tac-ing the new one in place before test fitting for clearances
Untitled by Connor Rhoades, on Flickr

It sucked
Untitled by Connor Rhoades, on Flickr

But finally we arrived at this
Untitled by Connor Rhoades, on Flickr

And then dropped the radiator in place to check for clearances too
Untitled by Connor Rhoades, on Flickr

So everything looks ok. I can play with the fitment of things later when I get the fiberglass in. I still need to disassemble and full weld the entire thing together. Need to pick up some sheet metal to weld some of the gaps. Should be ok though. Even with my welder set on the lowest setting, I struggle to weld sheet metal haha.

We're getting there though.

 

[Dezert4Runner]

Are you running mixed CO2/ Argon or straight CO2? .030 wire? Straight CO2 is supposed to burn a little hotter so using C25 and the smallest diameter wire the Hobart wire drive roll will accept (.024?) is your best bet to help with not burning through thin sheet metal work. Nice work so far.

 

[4Running Daily]

Are you running mixed CO2/ Argon or straight CO2? .030 wire? Straight CO2 is supposed to burn a little hotter so using C25 and the smallest diameter wire the Hobart wire drive roll will accept (.024?) is your best bet to help with not burning through thin sheet metal work. Nice work so far.

Mixed and .030". Didn't think about getting smaller wire. Thats a lot of effort. Probably a good call though.

Thanks!

 

[absalom]

Mixed and .030". Didn't think about getting smaller wire. Thats a lot of effort. Probably a good call though.

Thanks!

Bow down to the master of un****ing metal.

 

[4Running Daily]

Proud to announce our partnership with...


















Savage Off-Road

We'll be utilizing their skid plates and rear bumper! Very excited to work with Roy on this and show off their kick ass products.

 

[4Running Daily]

Time for some really ugly pics.

Obviously the core supports didn't line up perfectly. Or really even close. I was mostly concerned about the top core support "horns" because that's where the fenders bolt up to. Anyways the gaps were massive

Untitled by Connor Rhoades, on Flickr

Keep in mind though, for our purposes, no one really cares. But still I wanted it to look better and be stronger haha.

So I bent up some 16 gauge steel and lap welded the gaps.

Untitled by Connor Rhoades, on Flickr

Some were better than others. I'm not the greatest welder, but I'll grind and try again until I'm happy with strength.

I was proud of this vertical weld. Upside down is hard haha.
Untitled by Connor Rhoades, on Flickr

The biggest reason I even took on this partnership with SRQ was to gain experience building something that I could be proud of. So it's all a big learning experience.

Anyways, I welded the entire thing and then sealed it using a relatively new panel sealer from Loctite. I like it!

Untitled by Connor Rhoades, on Flickr

I'm going to coat it all in bedliner and you'll never even know.

One side took 4 hours haha.

 

[4Running Daily]

PRP steering wheel
Untitled by Connor Rhoades, on Flickr
Untitled by Connor Rhoades, on Flickr
Untitled by Connor Rhoades, on Flickr

 

[squishmitten]

Man that's a lot of progress for such a short time! Keep up the good work, I'm in Chandler, would love to come help out if I can ever get some free time away from work/school

 

[JBurt]

Subb'd! I've got to make it to KOH next year.

 

[theesotericone]

Proud to announce our partnership with...




Savage Off-Road

His skids and bumper can take a pounding. I have both and just pounded the crap out of them for 33 miles on the Dusy. The skids survived just fine. The bumper got just a tiny bit bent. For how many hard hits it took I was impressed it survived at all.

 

[4Running Daily]

His skids and bumper can take a pounding. I have both and just pounded the crap out of them for 33 miles on the Dusy. The skids survived just fine. The bumper got just a tiny bit bent. For how many hard hits it took I was impressed it survived at all.

They are awesome. I've ran them on my own rig for years! And Roy's customer service is unmatched.

DSC_0206 by Connor Rhoades, on Flickr

 

[4Running Daily]

Ok continuing on with the progress.

Colormatch it
Untitled by Connor Rhoades, on Flickr

Next up was to mount these coolers somehow. I zip-tied to get a rough position
Untitled by Connor Rhoades, on Flickr

Weld up an 1/8" bracket
Untitled by Connor Rhoades, on Flickr

Corner bracket
Untitled by Connor Rhoades, on Flickr

Keep in mind, these brackets are welded in place with studs welded on the backside. So the entire cooler just slides on, and bolts down with 4 nuts. Super easy to remove if we needed to quickly.

Both sides done:
Untitled by Connor Rhoades, on Flickr

Black hose (left side) is transmission cooler. Red hose (right side) is power steering.

Gonna pull everything off and paint the brackets etc.

 

[Mzs14]

Nice progress thus far, have you thought about any isolaters for those coolers? I couldn’t tell from the pictures but it would suck for the cooler to start leaking from the vibrations on the plates and core.

 

[Plastics guy]

Great job with that front end, looks great and will more than be strong enough with all the tedious fill plates you cut and added.

FYI If you guys end up needed any custom spacers, grommets, isolators, vibration pads or anything made of Rubber, Plastic, Silicone or epoxies. I can help you guys out with that too.

You can simply send me a CAD or a sketch on a napkin or give me a call, i don't care. I keep it easy

 

[4Running Daily]

Best update yet:

First, color match the brackets
Untitled by Connor Rhoades, on Flickr

Rubber isolators are a good call. I'll have to look in to that.

Close to factory
Untitled by Connor Rhoades, on Flickr

Hook up the lines and wiring harness
Untitled by Connor Rhoades, on Flickr

Fire her up and drive her to buy some beer
Untitled by Connor Rhoades, on Flickr














She is not the prettiest yet, but she'll get there once SRQ orders up wheels, tires, and fiberglass fenders. I'm off to start designing the front suspension. Diffs will be pulled and re-geared. Steering rack will be replaced. List goes on and on.

Anyways. I want to drive it for a couple days before pulling it all apart again.
So here she is

Untitled by Connor Rhoades, on Flickr
Untitled by Connor Rhoades, on Flickr
Untitled by Connor Rhoades, on Flickr
Untitled by Connor Rhoades, on Flickr

 

[onemanarmy]

awesome start.

will be following along

 

[AssBurns]

Nice progress guys! I'm looking forward to seeing the build progress, especially what you come up with for the suspension setup. Good luck!op2:

 

[JWaldz]

[MENTION=75445]4Running Daily[/MENTION]

The external coolers obviously provide extra cooling, but were you worried about blocking typical front air flow to the actual radiator with those mounting plates?

 

[4Running Daily]

[MENTION=75445]4Running Daily[/MENTION]

The external coolers obviously provide extra cooling, but were you worried about blocking typical front air flow to the actual radiator with those mounting plates?

Ya I thought about it. But this is one of the largest radiators Toyota sells, and a quarter inch thicker than every aftermarket one. I liked how tucked I could get them and how much welding area I had. So I didn't waste anymore time building a more complicated mount. Worst case, I can always drill some speed holes in the plate.

 

[SRQ-Runner]

Two new sponsors!!

Super happy to have True North Fabrications (front bumper) and McNeil Racing (fiberglass fenders) on board!​