Steel City Racing: King of the Hammers 2019 Toyota 4Runner IFS 4600 Build Thread

[Charles4x4]

Update:
Over the past 2-days, Otwell has been knocking out our Frame Mounts (this took a TON of effort), side protection bars, and vertical windshield bracing. I'll let the pics speak for themselves:

Current Helmet Headroom on 5'11" Person is 4-5":

Frame Mounts using Grade 8 1/2" x 2" Hardware (All 3 on Passenger Side shown):

Interior Sandwich Plates to Frame Mounts:

Side Protection Bars (set at top of Seat Cushion height):

Random B-Pillar Floor Brace to show where seats will likely end up. Note Otwell is making the mounts to tilt the seats back 10deg back for comfort and visibility reasons:

I was able to borrow a GoPro Hero 4 Black from a friend and picked up (2) 128 GB MicroCards so we can hopefully record the full race. This will be mounted using a GoPro 1.5" to 2.5" Roll Cage mount - likely on the Dash Bar:

Finally, I finished sync'ing our Dual XGPS160 to the iPad Pro, downloaded LeadNav Software, and purchased the LeadNav Pro Pack Annual subscription. For navigation, I really can't do anything else till the Course Maps are released on Friday 2/1 at 8pm PT from PCI Race Radios. We plan to start pre-running on Saturday 2/2.

 

[Charles4x4]

The cage.. man oh man! Nice! Nice! Nice!

Awesomeness!!!

Thanks everyone!

 

[Charles4x4]

Our team is excited to announce another sponsor: Pro Eagle Jacks. We'll be running their 2 Ton "The Beast" Big Wheel Jack and Bed Mount on the car at KOH.

The Beast:

Bed/Floor Mount:

After speaking with Hobie about this a few weeks back, we both felt a Pro Eagle was the right choice for KOH. It does weight a bit more, but is much safer, faster, and more compact than alternative Scissor, Bottle, or Hi-Lift Jack options.

Let's hope we don't have to use it during the race!

My Co-Driver for EMC, Matt Tatum is a Professional Firefighter and Paramedic. He handled our First Aid Kit - the bag is from Rago Fabrication:

 

[Quantumkiwi]

Our team is excited to announce another sponsor: Pro Eagle Jacks. We'll be running their 2 Ton "The Beast" Big Wheel Jack and Bed Mount on the car at KOH.

Looks cool.
Hmm, I think I'm going to have to weld a block like that for my floor jack now that I'm lifted. Its starting to struggle a bit on some jack points when getting up high.

 

[YetiX]

Looks cool.
Hmm, I think I'm going to have to weld a block like that for my floor jack now that I'm lifted. Its starting to struggle a bit on some jack points when getting up high.

Me too. I was going to get a Hi-Lift but I keep hearing scary stories and now these keep popping up.

 

[Quantumkiwi]

Me too. I was going to get a Hi-Lift but I keep hearing scary stories and now these keep popping up.

You should still get a highlift and learn to use it safely, there are situations where they are invaluable. But having a bottle jack for small stuff out on the trail and a shop jack like this is also nice.

 

[WhiteBoomer04]

Frame Mounts using Grade 8 1/2" x 2" Hardware (All 3 on Passenger Side shown):

Not a hater, just asking so I understand - won't the sandwiching of the body (floor pan) between the interior "legs" and the exterior mount to frame prevent the body from flexing? Will that cause problems with all the constant flexing the body will be doing in relation to the frame? I would think that might cause tearing on the thin sheet metal sandwiched in between.

 

[Inv4drZm]

Not a hater, just asking so I understand - won't the sandwiching of the body (floor pan) between the interior "legs" and the exterior mount to frame prevent the body from flexing? Will that cause problems with all the constant flexing the body will be doing in relation to the frame? I would think that might cause tearing on the thin sheet metal sandwiched in between.

With all the internal tube work and lower cross bracing, the body itself should be really stiff. So mounting it solid to the frame directly where the tubes mount to the body should actually add to the frame's stiffness. It all becomes one unit at that point. If it was just a single hoop or 4 point cage I could see tons of issues from that if it was mounted to the frame.

Next question is, are you going to remove the rubber body mount bushings and replace with solid blocks too?

 

[Charles4x4]

Next question is, are you going to remove the rubber body mount bushings and replace with solid blocks too?

Right now we aren't planning on altering the stock body mounts. Until a few weeks ago, it wasn't allowed. It is now allowed, but we don't see many benefits and have a ton of other stuff to knock out before the race. So, probably not.

 

[Charles4x4]

Shot Update on Yesterday's Progress:
The A-Team as there yesterday working on the 4Runner. Matt with RockSolidToys, Wyatt with RockSolidToys, BigMike with Marlin Crawler, and Robert with Otwell Welding and Fabrication.

Robert Otwell doing what he does best:

Artec Jaz Pro Sport Fuel Cell Mount being integrated:

Fuel Cell Test Fitting:

I'll be working on the final fuel cell hook-up next week along with some Aeromotive Phantom enhancements. Per a call with JT this morning, I need to add a ball valve on the Supply line. I ordered one that will be there on Mon.

 

[WhiteBoomer04]

There's a motley crew lol

 

[Charles4x4]

Update:

Starting Monday, I will have less and less time to update this build thread since I'll finally be on site in CA helping the team. I know not all of you like Facebook or Instagram, but it much simply more efficient for me to post quick pictures there while we are in the final stretch crunch of the build. So, if you can, follow us on FB/IG to stay up to date.

Also, these build threads will likely lag from now until race day, so don't panic if you don't see regular updates. We'll be working hard and will be on the start line on Wed Feb 6th!

Update on Otwell's Work:

Here's where we decided the spare will go for KOH:

Note that we test fit a ton of potential locations in both the Cargo and Passenger area, but ultimately decided this is the best spot for weight, COG, and visibility reasons.

Fuel Firewall per Ultra4 Rules is Done except for metallic tape we'll apply to perimeter:

And here is the Top Half of the B-Pillar Triangulation. I spoke with Otwell tonight and we decided to get rid of the middle vertical brace - it was overkill, weight, and hurt visibility/accessibility. So it'll just be an X when the Bottom Half is done:

 

[Charles4x4]

Continued from above...

Update on RockSolidToys Work:
The team has been crushing it the past few weeks. Matt and Wyatt put in 2-days last week and 3-days this week. Wyatt brought the Full RST Team out today to stay on schedule.

Per the posts above, last week they stripped the rear end and pull the Toyota T-Case. Then they started working on the Atlas II.

Atlas II Shifter positioning:

If you look closely through the cage bars, you can see the Shifter Base they fabricated:

Today the Dynatrac ProRock 60 finally got some attention - it's a beast!

Here is a "KOH Proof" reinforced version of RockSolidToys Rear 4-Link brackets:

Upper and Lower Frame Mounts are Done:

Dynatrac ProRock 60 is Slid into Place and you can also see the Atlas II in position in this pic:

Lower Axle Mounts are Done:

Action shot of RockSolidToys and Otwell doing what they do best:

We also got to check out the Icon 2.5" Rear Shocks (12" Travel) with RR and CDCV (on the fly tuning). They are impressive!

The team is taking off tomorrow, but we'll be hitting it hard on Monday and RST is back at Otwell's on Wednesday.

 

[Charles4x4]

Quick No-Pictures Update:
- Otwell finished the cage on Mon. Pics on FB/IG
- After my flight got in and I drove over from LAX, Otwell and I spent all of Monday night inventorying all the parts and To-Do's left on the car.

- Today I finished gutting the final components of the 4Runner (Doors, Glass, Random wiring, etc).

- Otwell got the Passenger Seat completely done - it's in position, mounted to the frame, harnesses done, etc.

- Otwell is 50% done filling in the sunroof and finished a quick Air Pumper mount.

- I finished also making all Aeromotive upgrades to our fuel cell including their new Apex siphon system to ensure no fuel starvation during the race.

- I also got the PowerTank filled and picked up all the random parts we will need from the hardware store (hose clamps, grade 8 hardware, light blue paint for number plates) etc.)

Tomorrow RockSolidToys and Otwell are both in the shop working on final fabrication and I'm working on more random stuff.

I admit that I was exhausted from the trip and time zone change today and simply forgot to take a bunch of pictures today. I'll try to do better tomorrow.

I wake up early to pick up all our spare Tires/Wheels - they have been at one of Marlin and BigMike's friends houses for a few months now.

 

[Charles4x4]

I have to get to the shop, but wanted to post a few recent pics for anyone who isn't on FB/IG:

Cage is done - Otwell is awesome! Lots of Triangulation:

Aeromotive Phantom Jet Siphon to add second fuel pick-up at opposite side of tank:

Sunroof Patch:

RockSolidToys Crossmember Mods:

Mounting these KMC XD222 Enduro Beadlocks is painful. The bolts move on you as you tighten. Taking me way too long to get these mounted. I'm only working on them at night after everyone else is gone:

3 Extinguishers mounted on Drake Quick Release mounts:

PRP Seats, PRP Harnesses, Rugged Radios M3 Pumper are in:

More to come.

 

[Charles4x4]

The team crushed it today. We got ahead of our To-Do list and for once we all got to leave the shop early around dinner time to get some rest before tomorrow's final push.

Updates:
Otwell Built spare tire mount:

Otwell Built ARB HD Air Compressor Mount in engine compartment for Air Lockers (and backup onboard air to PowerTank if ever needed):

Otwell Built T-Bar Handle + Navigation Mount with Quick Release. The T-Bar locks/unlocks and rotates up and down:
- Down for the co-driver to hold onto while racing
- Up past the windshield when we need to get out.

Currie AntiRock Rear Sway Bar goes on tomorrow:

Otwell Built Pro Eagle Big Wheel Jack Mount with Quick Release:

SFI Compliant (almost as hard as the roll bar itself) Roll Bar Padding installed above all Helmet areas:

RockSolidToys Rear 4-Link is tacked in (will be finish welded tomorrow):

Atlas II is done except we just need to connect shifter cables to shifter assembly built by RockSolidToys.

Tomorrow we have 4 teams working simultaneously as the Final Big Push to finish everything except Exhaust, Driveshafts (done, but not in hand yet), and Testing. If we don't finish, [MENTION=3485]rusty[/MENTION]nailjustin and our shared pit crew will come help knock out anything left on Sun.

The car is only a few minutes from the Lakebed now. We hope to be testing in "similar terrain" early next week. Then the wrap late next week and race prep begins next weekend.

 

[WhiteBoomer04]

Thanks for the updates. Keeping fingers and toes crossed that all falls into place. You certainly have an A-Team there.

 

[Ida4runner]

Awesome build! can we get some outside overall pictures? Thanks for keeping us posted.

 

[Charles4x4]

We've been at the shop 12-15 hours a day, so I'm going to make this post brief:

8 Tires/Wheels are done (7 pictured + 1 in car):

Fuel system is back in and done:

PowerTank is installed:

Wiring Fun:

Atlas II shifters and RockSolidToys made shifter box done:

Got 10-mins of work left on the Atlas II (fluids and a few connections):

Justin Reece and Team came out to help today - it was a HUGE boost to the build. A few other team members ended up with a conflict, so having Justin, Bird, Andrew, and Josh there was a massive help along with Robert Otwell:

Interior is Done:

Front Suspension is Done (huge thanks to Justin and Team here), but I'm still waiting for the release to be approved so no pics just yet.

Tomorrow we have to finish the rear suspension and install the driveshafts. We decided to cut the truss down and drop the upper links down to pick up a few more inches of up travel.

We also have to get the car to an exhaust shop tomorrow. We hope to have time to do some testing tomorrow, Friday, and this coming weekend. It gets wrapped this Wed/Thurs.

 

[Bumbo]

I envy your build... so glad you did this to a 4Runner and not another Tacoma.

Really... thanks for sharing. If I ever accomplished even half of what you did here I would be "living the dream"