Sunpilot's 4Runner Official Build Thread

[SunPilot]

I finished welding the sides completely, tacked on the small tabs inside to hold the lights, secure the bumper, etc. Did lots of grinding and gave it a coat of primer
20170124_121340 by sunpilot1, on Flickr
20170124_121348 by sunpilot1, on Flickr
20170124_121356 by sunpilot1, on Flickr
20170125_144038 by sunpilot1, on Flickr
20170125_144047 by sunpilot1, on Flickr
20170125_144055 by sunpilot1, on Flickr
20170125_144104 by sunpilot1, on Flickr20170125_144112 by sunpilot1, on Flickr

Now that I am satisfied, I have to weld the top pieces on, finish grinding and painting. I should be done early next week the way I work!

 

[SunPilot]

Finally finished the bumper build.

It took awhile, but I managed to finish my first fabrication project. Pretty proud of the way it turned out. Here are some pics of the end of the project:
Welding the top on the bumper
20170201_131532 by sunpilot1, on Flickr

Lots of grinding to do
20170201_131539 by sunpilot1, on Flickr
20170201_131549 by sunpilot1, on Flickr
20170201_131556 by sunpilot1, on Flickr


Gave it a coat of primer
20170204_121638 by sunpilot1, on Flickr

I used Rustoleum hammered black for the finish
20170204_121647 by sunpilot1, on Flickr

Finally got it bolted up to the runner
20170208_094849 by sunpilot1, on Flickr
20170208_094858 by sunpilot1, on Flickr

I still have to wire the winch and install the synthetic line...also have to make a bracket to secure the inner fender liners and trim them
20170208_160525 by sunpilot1, on Flickr

New fog lights
20170208_160550 by sunpilot1, on Flickr

Rough Country dual row light bar is very bright, and white! Especially compared to my halogen headlights. Have to upgrade the headlights with HIDs
20170208_160609 by sunpilot1, on Flickr

Headlights at night
20170208_233616 by sunpilot1, on Flickr


With the fogs on
20170208_233627 by sunpilot1, on Flickr

On the street...just headlights
20170208_233751 by sunpilot1, on Flickr

With fogs (need to adjust them)
20170208_233756 by sunpilot1, on Flickr
20170208_233802 by sunpilot1, on Flickr

Just the 30" light bar...no headlights!
20170208_233810 by sunpilot1, on Flickr
20170208_233935 by sunpilot1, on Flickr

In front of my garage
20170208_234053 by sunpilot1, on Flickr

The light bar is awesome!
20170208_234007 by sunpilot1, on Flickr

 

[blackoutt]

Lookin good! I think the outside corners are a little too high profile but if you added some hoops it would blend just fine. I'm also a fan of minimalist bumpers so its just my opinion, I'm actually really jealous that you build such a good looking bumper yourself and looks like you enjoyed the project too.

 

[SunPilot]

Lookin good! I think the outside corners are a little too high profile but if you added some hoops it would blend just fine. I'm also a fan of minimalist bumpers so its just my opinion, I'm actually really jealous that you build such a good looking bumper yourself and looks like you enjoyed the project too.

Thanks for the input. I actually thought about softening the pointy corner. I may take the bumper off one day and fix it. It would be easy, just weld a piece or two at a 45° angle across the corner inside the bumper, then cut off the extra metal, and repaint. That would give me another angle and maybe make it look better? I'm not into hoops, so that won't happen
20170208_094916 by sunpilot1, on Flickr

 

[blackoutt]

Yeah I think one more angle would soften up that broad profile at the corners. I agree if you have no use for hoops then don't run hoops!

 

[SunPilot]

Yeah I think one more angle would soften up that broad profile at the corners. I agree if you have no use for hoops then don't run hoops!

I think you're right. Not much work at all...I'll just weld the pieces inside the bumper and cut off the excess... Maybe a day's work

Have other things more pressing right now...getting ready to do timing belt/water pump and some other engine related things

 

[blackoutt]

I have faith that you'll be able to do it easy peasy.

Timing belt and water pump is a nice big job too, lots of bolts but again just nuts and bolts and overall pretty simple. I'd highly recommend the Toyota OEM water pump and gasket, I had fit issues with the gasket in my Gates kit, resolved that then 10k miles later the pump was shot. Went with OEM (hastily installed the night we were supposed to be leaving on a two week road trip) and put another 10k on no issues. Blackworks writeup page on here is pretty accurate, there's another one from M3pink (?) I think somewhere that's good too. While there's debate about which timing marks on the cams to line up just line them up somewhere, mark the belt and put the new on the same and it doesn't matter.

 

[SunPilot]

I have faith that you'll be able to do it easy peasy.

Timing belt and water pump is a nice big job too, lots of bolts but again just nuts and bolts and overall pretty simple. I'd highly recommend the Toyota OEM water pump and gasket, I had fit issues with the gasket in my Gates kit, resolved that then 10k miles later the pump was shot. Went with OEM (hastily installed the night we were supposed to be leaving on a two week road trip) and put another 10k on no issues. Blackworks writeup page on here is pretty accurate, there's another one from M3pink (?) I think somewhere that's good too. While there's debate about which timing marks on the cams to line up just line them up somewhere, mark the belt and put the new on the same and it doesn't matter.

I already have the belt and pump kit, and I believe the pump is o.e. I also have new spark plugs, valve cover gaskets (gonna check valve clearances while I have the engine partially disassembled, new PCV, and clean MAF and throttle body...should be some fun!

 

[gm350reratliff]

I just read through your build, very nice! Great job on that bumper! I also want to reinforce the bumper mounting brackets before I install the Relentless Fab DIY bumper I've been working on and I might use some of your ideas.

 

[SunPilot]

I just read through your build, very nice! Great job on that bumper! I also want to reinforce the bumper mounting brackets before I install the Relentless Fab DIY bumper I've been working on and I might use some of your ideas.

Anything I can do to help, just ask. I believe in sharing knowledge. Good luck

 

[Raymond_q]

Very cool build! By the way how did the timing belt job go?

 

[SirRah]

That's one seriously good looking bumper! I can dig it!

I wish I had the time and patience to do it myself.

 

[SunPilot]

Very cool build! By the way how did the timing belt job go?

Still in the middle of the engine work...doing more than just the belt...cleaning MAF, throttle body, adjusting/checking valve clearance, oil change, anti freeze, spark plugs, etc. Should finish Saturday if I don't get sidelined again!

Then I'm starting to build my rear bumper and doing axle cv's...I tore a boot doing my lift install, so decided to replace both with lifetime from NAPA and rebuild my old ones for spare. never ends! LOL

 

[SunPilot]

That's one seriously good looking bumper! I can dig it!

I wish I had the time and patience to do it myself.

Time and patience are truly a blessing. I never had either until I retired!

 

[SunPilot]

Starting my rear bumper project

This week I finally got around to starting my rear bumper project.
I'm building an overland expedition rig, so I'm not really worried about heavy armor on the sides as much as functionality.
My goals are:
*dual swing outs, one to carry my spare tire and the other to carry extra fuel and assorted trail items.
*Try to improve the ground clearance and give better departure angle
*Access to the roof
*Utilize the space underneath (from removal of spare tire) for a water tank
*Functionality is important, but I'll try to make it somewhat aesthetically pleasing too.

My first order of business was to remove the rear bumper surround
20170301_151818 by sunpilot1, on Flickr
The rear frame crossmember is very beefy and heavy, and supports the tow hitch receiver. I will cut that off to gain some clearance, and to simplify my new bumper attachment.

Before I did any cutting, I measured the departure angles at the back. After my lift being installed and with the plastic bumper surround removed, the angle measured about 39° at the frame horn

The angle measured at the tow hitch receiver was less because it hangs down and further to the rear...it came in at about 34°. Both measurements are pretty respectable already and I hope to improve on them a little bit

 

[SunPilot]

Cut off the rear cross member

I cut off the rear cross member. It is a very beefy and heavy design, but since it curved, it really didn't fit into my plans. I will go for a cross member that is more straight, and holds the tow receiver up higher. I'll fabricate a new member, cross bracing, and pivot supports for my swing outs. Then I will fab a lightweight and simple bumper to cover it all. Still haven't any idea what to do to tie the bumper into the side panels and make it look nice, but I'll figure something out.
20170301_144011 by sunpilot1, on Flickr
20170301_144024 by sunpilot1, on Flickr

I will cut off the old bracket underneath that used to support the spare tire. That will give me a lot of room to mount some sort of fresh water tank in that space. I'm hoping to get over 10 gallons of water storage under there. I'll probably put an electric pump in the tank and route it to the back somewhere so I can have water for cooking, etc. I also cut the resonator off and some of the tailpipe. I will route the exhaust out the side near the tire and up higher. It was the low point in the rear.
20170301_144037 by sunpilot1, on Flickr

I ground off all the old welds and left myself with a nice clean frame to work with. Monday I'll head over the the metal store and get the plate and tubing needed to make the new cross member and supports.
20170301_151818 by sunpilot1, on Flickr
20170301_151757 by sunpilot1, on Flickr

 

[Slowgoat]

Subd

 

[alia176]

This guy did a real neat jerry can holder under the rear cargo area, might inspire you in some ways!

https://forum.ih8mud.com/threads/our-panam-rig-build-tread.884857/page-4#post-10396625

 

[SunPilot]

This guy did a real neat jerry can holder under the rear cargo area, might inspire you in some ways!

https://forum.ih8mud.com/threads/our-panam-rig-build-tread.884857/page-4#post-10396625

That's a cool idea with the swing down access. I think I will be putting my extra fuel on the bumper swing. I will keep my water there, that way I can use a permanent pump and no hassles. It does give me some ideas though...thanks for sharing.

 

[dgmorr]

Sub'd