Sunpilot's 4Runner Official Build Thread

I have some wiring to do next, and in fact, I will be wiring a second battery, so I will have a write-up on that coming soon.
This is the finished product. I am very happy, and my wallet is liking the cost! I know some after-market racks go for well over a thousand bucks...I'm in at well under $200 including the expensive paint. Merry Christmas to me LOL
20171212_132856 by sunpilot1, on Flickr
20171212_132858 by sunpilot1, on Flickr
20171212_132847 by sunpilot1, on Flickr
20171212_133631 by sunpilot1, on Flickr
20171212_133627 by sunpilot1, on Flickr
20171212_133636 by sunpilot1, on Flickr
 
Very impressive work, Sunpilot! Seems like you put in a lot of thought and research and everything seems to be coming out excellent! Keep it up!
 
My Dual Battery Setup and build Info

These next postings will contain a more detailed description of my dual battery installation, components, and photos
 
I started the dual battery upgrade by looking over options for placement of battery. I see most aftermarket systems place the second battery on the right fender behind the air cleaner. After measuring clearances in other areas, I decided to use that same space.

Before I started on the battery tray, I made some brackets to carry the other components. I utilized the space behind the 4Runner's fuse box on the left fender... as seen in this photo
20180307_111843 by sunpilot1, on Flickr
There is space here, but if the components are bolted to the fender they will be too low to service.
I decided that I would build an elevated platform for the inline fuse and the relay in this area.
20180307_111853 by sunpilot1, on Flickr
I had some square tubing left over from my roof rack build, so I made an elevated platform that could be bolted to the fender
20180307_112756 by sunpilot1, on Flickr
 
After finishing the component perches I jumped to the right fender to build a battery tray. I looked on line for ready made trays, and some of them ran upwards of $200 for the kit. Whew!

First, I took off the air cleaner box to open the space for my installation.
20180313_110318 by sunpilot1, on Flickr
It's a small space really. I was utilizing the Odyssey 34 PC1500 batteries, so careful measurement showed there was enough room. I also noticed that the fender has some give, or play, in this area. It is a concern when you realize there will be a 50# battery sitting there and the rig will be going down some less than smooth roads. Two bolts aren't enough to secure a battery tray in my opinion, especially when the back side of the tray isn't really supported much, since the fender drops away in that area. I drilled a hole in the flat stamped sections of fender to use as mounting locations
20180313_110309a by sunpilot1, on Flickr
20180313_110312a by sunpilot1, on Flickr
A bolt will go through the fender at the red arrows, and I also used the ground bolt in the upper fender to hang a tray support in the back, at the arrow location in this photo.
20180313_125305a by sunpilot1, on Flickr
You can visualize how the tray will be placed after I build a bracket to hold it.
 
As I was measuring the space, I realized that the air conditioning pipes coming from the firewall would possibly interfere with the battery tray. The clearance was very tight and I didn't want any possibility of rubbing, so I decided to build a bracket of sorts to raise the tray up. Raising the tray gives plenty of clearance. Here are some pics of the bracket I started to fabricate.
20180314_141438 by sunpilot1, on Flickr
20180314_141444 by sunpilot1, on Flickr
20180314_141449 by sunpilot1, on Flickr

It might not look pretty, but it resides below the tray and will provide great support. The bracket is made from 1" square tube I had left over from my roof rack build, and it will lift the battery 1" off the fender.
 
Here are some photos of the completed bracket. I put a couple coats of primer on, then some gloss black
20180321_132810 by sunpilot1, on Flickr
here is a better view of the support at the fender, utilizing the ground bolt already in the fender
20180321_132823 by sunpilot1, on Flickr
I have as many bolts in the bracket as I could get. It's amazing at how much stiffer the fender is now, and I have no concerns about putting the heavy battery in that area now.
20180321_132813 by sunpilot1, on Flickr
 
Here is the initial fitting of the battery tray.
20180319_141423 by sunpilot1, on Flickr
After fitting I realized I cut it an inch or so short, so I had to extend it a bit. It is nothing more than a piece of flat plate... 10ga. steel. You can see that it will simply bolt to the bracket underneath. I welded blind nuts in the bracket to make the bolting easy.
here is the tray already extended. I welded simple angles on the tray to position the battery and make sure it doesn't slide around.
20180322_111721 by sunpilot1, on Flickr
I purchased a set of battery hold down bolts at O'Rielly's Auto Parts for about $3. If you look, I also welded a piece of the tubing at the back of the tray that supports that side, and it bolts to the fender also.
20180322_111701 by sunpilot1, on Flickr
 
Here it is, all snug and clamped down. I made a simple clamp for the top out of plate steel and a couple angles welded to the bottom. I used some rubber I had lying around to cushion the top clamp. It holds very well without putting undo pressure on the plastic battery case.

The unit is up and running, and I have a few more little things to do, but it works very well and I am happy that I can go out and spend some time off the grid and have power. I will be installing a solar panel to my setup at a later time. Thanks for reading my build!
20180325_134959 by sunpilot1, on Flickr
 
oh my God

Wow! Everything seriously wow.

Would you mind showing a pic of the valve numbers for the driver side?
I didn't see much in your extensive write up about lower ball joints or steering components. How is yours doing on those fronts? I saw the two giant fuses and assumed you had a killer sound system but I see now. Have you gotten your winch in a downpour yet?
 
cloud said:
Wow! Everything seriously wow.

Would you mind showing a pic of the valve numbers for the driver side?
I didn't see much in your extensive write up about lower ball joints or steering components. How is yours doing on those fronts? I saw the two giant fuses and assumed you had a killer sound system but I see now. Have you gotten your winch in a downpour yet?
Click to expand...

The numbers on the coils are there to help me put them back in their original place. They didn't have any other significance.

I didn't do the lower ball joints, as mine were still tight and in good shape. I did go to uniballs in the new upper arms though. My suspension is doing very well. I'm actually surprised at how smooth and comfortable it is and the truck tracks straight as an arrow. I'm very happy.

The fuses are there to protect the batteries from possibly shorting. I don't have a super sound system. My winch has been in the rain, although living in the desert we don't get many storms. So far all is well!
 
ARB Air Compressor Installation

Not much, really, to say about this install. I made some simple brackets that bolt on the fender behind the power steering reservoir. The ARB fits in there perfectly.
20180330_112357 by sunpilot1, on Flickr
20180330_112405 by sunpilot1, on Flickr
20180330_152448 by sunpilot1, on Flickr
I made an extension to get the air intake up higher, and also facilitate easier removal for cleaning.
20180330_152455 by sunpilot1, on Flickr
20180330_152459 by sunpilot1, on Flickr
I'm happy with the install. I have a switch on my overhead switch console in side the Runner to turn it on and off. It is more than adequate for the simple tasks I need... mainly airing up my 33" tires. I didn't see a need to spend double the money for the dual cylinder compressor, as I'm not running air tools.
 
My Roof Top Tent

I got my tent installed yesterday. Just trying to familiarize myself with it now.
I bought the 23Zero Litchfield model. It got some nice reviews, and I like the quality and conveniences that come with it. I'll let you know more after I actually get on the trail and use it... my views may change!
20180406_163505 by sunpilot1, on Flickr
20180406_171514 by sunpilot1, on Flickr
20180406_171528 by sunpilot1, on Flickr
When I initially fabricated my roof rack, I already had the dimensions for this tent, so the fit was exactly how I envisioned it. I built my roof rack in the back with just one level to get the tent closer to the roof for aerodynamics and to keep the weight lower. Seems to have worked out well.
Here are a few inside pics
20180406_171550 by sunpilot1, on Flickr
20180406_171553 by sunpilot1, on Flickr
There's plenty of room in there for two people, and even a dog. I didn't need anything larger.
This model comes with a single sky light as a standard feature. It also has a complete rain cover, which isn't shown in these pictures.
20180406_171555 by sunpilot1, on Flickr
20180406_171616a by sunpilot1, on Flickr
20180406_171622a by sunpilot1, on Flickr
Here are a few pics at night (bad quality... sorry). I already had my roof lights installed when I built the rack, and they worked as planned and privide a nice spread of light.
20180406_193407 by sunpilot1, on Flickr
20180406_193417 by sunpilot1, on Flickr
I tried the annex, but didn't take any pics of it. It is well made and is a nice large room. I could see an extra cot or two fitting in there. One nice feature of the annex, besides a full rubber floor, is the large zippered opening in the back that will let you access the vehicle's rear door from inside the annex! The annex is also a standard feature on this model.
 
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