Sunpilot's 4Runner Official Build Thread

[SunPilot]

Making and installing rear cross member and tow hitch

I bought a new tow hitch receiver and some steel for my new rear cross member. My goal is to tuck the cross member closer to the body to help with departure angles, etc. I incorporated the new tow receiver directly onto the cross member, lifting it a bit higher. Not sure what tow rating it will have, but I don't tow any large travel trailers, so it will certainly be adequate for my needs.

Along with the installation of the new cross member, I cut out the original under body tire carrier. That really opened up a nice space to add water tanks, etc. under there.
Fitting the cross member
20170308_142047 by sunpilot1, on Flickr
The design I came up with.
20170311_120621 by sunpilot1, on Flickr
20170311_120631 by sunpilot1, on Flickr

A look from underneath...sorry for the blurry pic
20170312_132129 by sunpilot1, on Flickr

Here you can see the large cavity that is left after cutting off the spare tire carrier
20170312_132150 by sunpilot1, on Flickr
20170312_132153 by sunpilot1, on Flickr

Here are a few pics of the cross member fitted and ready to be welded to the frame.
20170309_160609 by sunpilot1, on Flickr
20170309_160618 by sunpilot1, on Flickr
20170310_154237 by sunpilot1, on Flickr

My next step is to make some brackets that will attach on the outsides of the rear frame and carry the swing arms. They will be mounted directly to the frame and not depend on the bumper to support them. I'll be working on the supports and swing pivots early this week, so I should have some pics to share in a few days.

 

[dgmorr]

What kind of welder are you using?

 

[SunPilot]

Making my rear bumper swing arms

I have the rear cross member installed...now the next step is making the rear swing arms. I'm doing a dual swing system. The left side will carry my spare tire, and the right will carry extra fuel, jack, etc.

I don't want the hassle of greasing the arms, so I bought some oil impregnated bronze bushings and washers
20170315_111603 by sunpilot1, on Flickr

I bought a nice piece of 1" cold rolled stressproof round bar at my local metal store. I cut it into two pieces, which will become the removable hinge pins. They will simply drop down into the bushings and will be easily removed should I decide to remove the swing arms for any reason
20170316_114401 by sunpilot1, on Flickr

I pressed (hammered) the bushings into the dom tubing...nice and tight.
20170316_114415 by sunpilot1, on Flickr

The pins fit in with a few thousandths clearance...very snug, but not binding...
20170316_114439 by sunpilot1, on Flickr
20170316_114710 by sunpilot1, on Flickr

Here is a good idea of where the swing arms will ride...I'm fitting them into the proper location, and then I will make the supports for the pivots. My goal was to keep the pivots close to the frame and body, thus the angle in the arm. The angle will also allow the arms to open wider than the hatch giving me extra room when opened.
20170316_150919 by sunpilot1, on Flickr
20170316_150932 by sunpilot1, on Flickr
20170316_150947 by sunpilot1, on Flickr
20170316_150958 by sunpilot1, on Flickr

Here is a view of how the pivot will be below and behind the hatch. When the hatch is closed, the pivot and pin will be inaccessible, giving me security that no one will take the pin out and walk away with my tire or fuel cans.
20170316_151253 by sunpilot1, on Flickr


After I get the pivot brackets done and mounted I will make the actual bumper. It will be a simple plate bumper made of 10 ga. steel. The bumper will actually be a support for the swing arms when they are closed, taking stress off the pivots.

 

[SunPilot]

What kind of welder are you using?

I bought a Hobart 190 first welder I've ever owned...still learning

 

[dgmorr]

I bought a Hobart 190 first welder I've ever owned...still learning

How long have you been welding for? I've been contemplating doing a rear swingout build but I'm a bit of a noob. So far only made my roof rack, not something really critical.

 

[SunPilot]

How long have you been welding for? I've been contemplating doing a rear swingout build but I'm a bit of a noob. So far only made my roof rack, not something really critical.

I just started recently. Bought my 4Runner then decided to make an overland expedition rig out of it. I started adding up all the cost for the things I needed and it was astronomical. I bought the welder and some other tools and learned to use them. I've built my front bumper, almost finished with the rear now. The money I saved making the front bumper paid for the welder and the tools. Now, I am ahead of the game! Heck, I was a noob too... If you built your rack (one of my next projects) you can do a bumper. I've posted a ton of pics showing how I built mine, but you can do yours any way you desire. If you need any help or suggestions, please feel free to contact me.

 

[SunPilot]

Starting the final stages of the rear bumnper build.

I finally got the rear swing arm brackets made and welded to the frame. Now, the swing arms are in their proper position.
20170321_144428 by sunpilot1, on Flickr
20170321_144445 by sunpilot1, on Flickr

I am going to try and fit the new bumper shell (made from 10ga plate) over the cross member and have it blend in with the original bumper surround. The bumper shell will also support the swing arms when they are closed and I'm traveling. That is when the most stress is on the arms. I didn't want to build a completely metal bumper in the back because the ones I've seen always look a little boxy and don't seem to fit properly (my opinion only). I don't know how mine will turn out... Toyota's design of the rear doesn't lend itself to an easy bumper solution. No matter what, there will be compromises.
I trimmed the lower portion of the plastic shroud to fit over the parts I made. Now, I'm trying to fit the plate metal to make it look decent.
20170322_150311 by sunpilot1, on Flickr

The plastic won't cover the complete top of the bumper...I need room to remove the pin and top swing arm brackets in case I have to work on them. When the hatch is closed I think it will look decent.
20170322_150343 by sunpilot1, on Flickr

I will do the bottom of the bumper in 10ga plate and try to make it fit as best I can.
20170322_150410 by sunpilot1, on Flickr
20170322_150418 by sunpilot1, on Flickr
20170322_150328 by sunpilot1, on Flickr

I'll be working on the bumper shell for a few days... After I get it to where I'm satisfied, I will finish the swing arms. I have to make racks to hold the extra fuel cans on one side and the spare tire on the other side. Since the swing arms are easily removed, I can do that work on my bench with no problem.
Hell, it may not end up looking that great, but at a savings of $1500 or more that a purchased bumper would cost, I'm a happy guy!

 

[T4RNightHawk]

I could be entirely wrong but you might wanna check your tailgate clearance. My swing arm was placed about where yours is and I ended up having to move it out.

 

[SunPilot]

I could be entirely wrong but you might wanna check your tailgate clearance. My swing arm was placed about where yours is and I ended up having to move it out.

Are you referring to the clearance when the arms are open and you try to lift the hatch?

 

[T4RNightHawk]

Are you referring to the clearance when the arms are open and you try to lift the hatch?

No when everything is closed how close it is to the tailgate. Mine was like 1 cm off and whenever I went over bumps it would hit.

 

[SunPilot]

No when everything is closed how close it is to the tailgate. Mine was like 1 cm off and whenever I went over bumps it would hit.

Ah, gotcha. I believe when I designed it that the upright would clear the closest part of the hatch by about an inch. 1 cm is about 3/8". Did yours hit all the time, or just in very rugged use?

I'll double check to make sure...don't want any banging going on. That's one reason I didn't finish welding the swing arms...once I have everything else set, I can adjust the arms as required. I'll post a pic of the upright sitting on the arm later today. Thanks for the advice.

 

[SunPilot]

No when everything is closed how close it is to the tailgate. Mine was like 1 cm off and whenever I went over bumps it would hit.

I went out and took a pic. Here is my clearance, actually a bit over 1" This is where I anticipate the back of my upright being. Of course, the tire will be to the rear of that
20170323_122000 by sunpilot1, on Flickr
20170323_121843 by sunpilot1, on Flickr

My biggest concern is getting the tire mounted as close to the left tail light (so it doesn't block much of my rear view) without the tire hitting the taillight when the swing is opened. I may need to push the upright more towards the center to clear the light. It won't be a hassle for backing up because I will have a rear camera in place, but I like to see traffic while I'm moving. Guess I could put a separate video screen in the cab that always shows the rear camera view while I'm moving!

 

[T4RNightHawk]

It would hit on the shitty roads of Atlanta so I guess you could call that rugged. that's about where mine is once I moved it so you should be fine.

 

[BackOff]

Bonehead me posted this in dkyleb's build. DOH.
The deer damage sucked me in.


Bumpers look good.
I like the hidden hinge.

Just wanted to say, on my rear bumper its just a little to close to the hatch bottom edge and I get small rocks wedge themselves in and rip up the paint on the hatch.

/cheers

 

[SunPilot]

Bonehead me posted this in dkyleb's build. DOH.
The deer damage sucked me in.


Bumpers look good.
I like the hidden hinge.

Just wanted to say, on my rear bumper its just a little to close to the hatch bottom edge and I get small rocks wedge themselves in and rip up the paint on the hatch.

/cheers

Yep, I hear ya. I have about 1/2" under hatch... I'll think about that...thanks

 

[dkyleb]

Bonehead me posted this in dkyleb's build. DOH.
The deer damage sucked me in.


Bumpers look good.
I like the hidden hinge.

Just wanted to say, on my rear bumper its just a little to close to the hatch bottom edge and I get small rocks wedge themselves in and rip up the paint on the hatch.

/cheers

I was wondering WTF! Haha. Oddly enough, a rear swing out is my next build!

 

[SunPilot]

Rear Bumper Build Update

My rear bumper is almost finished. I test fitted the old plastic bumper cover with the new lower fenders I fabricated. Then I plastic welded some tabs on the cut bumper to fit into slots on the metal lowers.
20170405_115043 by sunpilot1, on Flickr
20170405_152503 by sunpilot1, on Flickr
20170405_152709 by sunpilot1, on Flickr
20170405_152441 by sunpilot1, on Flickr

They work perfectly. After I installed the plastic bumper and fit the tabs into the slots, there was no movement from the plastic at all.
I gave the lower bumper pieces a coat of paint
20170405_115037 by sunpilot1, on Flickr

Then I bolted the lowers on and fit the plastic bumper back on to finish the sides

It may not be the prettiest bumper around, but my goal was functionality and durability first. I'll be doing overland exploration in rough country and expect dings and scratches, etc. Made no sense to me to waste time doing a perfect job only to go out and ding it up. The build I did is simple and effective and can be easily repaired. I'm satisfied.

 

[SunPilot]

The workings of the swing arms

The swing arms are the important part of this build for me. They needed to be tough enough to carry the weight of the spare and extra fuel, etc., and easy enough to open and close with no hassle. I didn't want rattles, so I used some bump stops from a Jeep to cushion the swing arms when closed.
20170405_152749 by sunpilot1, on Flickr
20170405_152756 by sunpilot1, on Flickr

The arms are resting on some nylon blocks I cut from a sheet of 1/2" nylon I bought. They make the arms nice and tight with no rattle or movement when closed, and the nylon provides an extra support. That way the pivot isn't carrying the whole load when traveling.
20170327_114952 by sunpilot1, on Flickr
20170327_115004 by sunpilot1, on Flickr
20170327_131753 by sunpilot1, on Flickr

After I fitted the side pieces, I started on the spare tire mount for the left swing arm.
20170420_143103 by sunpilot1, on Flickr
20170420_143053 by sunpilot1, on Flickr

Initially I was going to buy a spare tire mounting plate, but they cost about $30 shipped...just for a simple round plate with some holes drilled in it. I opted to make my own. I didn't waste time making the plate perfectly round, it's job is to carry the spare and seldom seen anyway.
I bought some 1/2" grade 8 bolts and matching conical lug nuts. I found a PDF file on line with the Toyota bolt pattern and printed it out. The pattern was exact! Made drilling the bolt holes a piece of cake
20170422_090944 by sunpilot1, on Flickr

I angled the plate back slightly. This makes it easier to place the tire on the carrier and install the lug nuts without holding the tire in place with my hands.
I did a test fit and liked the way it came out
20170420_143449 by sunpilot1, on Flickr
20170420_143455 by sunpilot1, on Flickr

I put the tire on to make sure I had clearance between the tire and the body when opened.
20170420_144023 by sunpilot1, on Flickr
20170420_144042 by sunpilot1, on Flickr
20170420_144106 by sunpilot1, on Flickr
20170420_144058 by sunpilot1, on Flickr

Now, I'm painting the left swing arm, installing the left backup up light, and making plans for a stainless steel swing down shelf to mount on the backside of the tire carrier. It will be nice to have the swing down tables when out in the back country and making dinner, etc. I'll put a shelf on each swing arm. My fridge and stove will stay inside the back of the Runner and extend on slides for easy access. I also need to install a backup camera and relocate the license plate. I also have to come up with a latch system to keep the arms locked when on the road. That will happen on the right swing arm. My jerry can will be delivered on Monday, so I can do the right side next week and call the job complete.

 

[NinjaOne]

Now, I'm painting the left swing arm, installing the left backup up light, and making plans for a stainless steel swing down shelf to mount on the backside of the tire carrier. It will be nice to have the swing down tables when out in the back country and making dinner, etc. I'll put a shelf on each swing arm. My fridge and stove will stay inside the back of the Runner and extend on slides for easy access. I also need to install a backup camera and relocate the license plate. I also have to come up with a latch system to keep the arms locked when on the road. That will happen on the right swing arm. My jerry can will be delivered on Monday, so I can do the right side next week and call the job complete.

Looks great. Front bumper looks a little snug to the front fenders, you tested it under flex? My bumper currently hits my fenders, considering 1/2" bodylift for extra clearance or adjusting the bumper slightly

For the rear swingout(s), you may want to consider adding something to lock them open for off-camber situations. Make me a matching carrier?

 

[SunPilot]

Looks great. Front bumper looks a little snug to the front fenders, you tested it under flex? My bumper currently hits my fenders, considering 1/2" bodylift for extra clearance or adjusting the bumper slightly

For the rear swingout(s), you may want to consider adding something to lock them open for off-camber situations. Make me a matching carrier?

I have about 1/2" gap between the bumper and the fender. I do not have a body lift, but if I did, I would have just made the bumper higher to eliminate the larger gap. There is also a bracket I made that secures the bumper to the fender on the side to keep it from moving. My mounts are pretty solid and the bumper plates are a decent gauge and I get no flex. I overbuild things a bit.

For the rear, I am installing a bump stop underneath to keep the arms from swinging out too much and I will have a lock in place to secure them when opened. Those are my next projects, along with the gas can holder and backup lights, etc.

I had fun building this, but not enough to start building more of them. I can give advice or help based on my experience to anyone that asks though.