Trailrazer Build

[trailrazer]

This has been a great forum with a wealth of information. I have searched and found some good answers, solutions and reviews of issues from users. There are a lot of helpful people here and it's been a very positive experience.

I bought my 2003 4runner at the beginning of April. It's a V6 SR5 4WD without the JBL and XREAS. It had 100K on it and all the major services had been completed. This is my first 4Runner and I am happy with it so far. My first mods were to install my Pioneer deck so I could use my iPod and bought some Husky Liners for the front and back.

My previous truck was a 2005 Dodge Ram Quad Cab 1500 4WD with a Hemi. I had a Fabtech 6" lift and 35" Toyo MT's on it. 9-10 MPG wasn't cutting it and had to make a change.

I've had some issues to correct and I'm making some lift modifications as well. Unfortunately it was raining the day I bought it and didn't notice all the corrosion and rust under it from it's lift in New York. I live in Oregon where we don't salt the roads. I spent the last several days with the bumpers off, angle grinder in hand and several rattle cans of primer and top coat.

The skid plates where horrible. I don't know how you folks back East deal with the rust. My OCD has gotten the best of me and it's driven my wife nuts. I'll be installing new poly sway bar bushings and end link bushings soon.

I'm concerned about the control arm bushings and other suspension bushings since there was an uncomfortable amount of rust. The steering is tight and the dealer did an alignment. They said everything was great. I don't feel confident in that though. The lower control arm bushings and dried out and cracked. I will probably wait on those.


Here are some pictures with more to come as my build progresses. My intention is to have a nice and clean 4Runner for use as a daily driver with camping trips, sticking to some fire roads and 2 track. I motorcycle ride off road.

After some thorough research, I decided on the FJ coils, 5100's and DayStar 2.5/1.5 spacers. Later I'll be installing the Spidertrax spacers and some bigger tires.

I have a few issues to repair. The rear window trim needs replaced all the way around. The top and side have some corrosion that's started. I also have to repair the seat adjustment bar on the back. It's rocking around a little. I found some solutions on the forum for both those issues.

Next week I'll hopefully have the suspension completed. I'll post up the pictures of it with the difference in stock. Any suggestions are helpful. I've got the bug and more stuff to come.

 

[trailrazer]

Day I bought it... didn't get this uploaded in the original post.

 

[rebelbowtie]

Wow that rust was really bad, look like some places the metal started to delaminate. Your wife should thank your OCD

 

[knightsfs4]

What did you use on that rust? What all did you do?

Jack

 

[trailrazer]

I used a 4 1/2" angle grinder with a knotted wire wheel. It took a while to get through it. I burned through one of the wire wheels. Luckily all the rust was down low. Everything up high was great. The frame had no soft spots so far that I could find. This was actually the only issue I could complain about.

I was going to use POR-15, but just used rattle cans of 2 primer coats and top coat. I was down to bare metal in most areas.

That was pretty tough getting the grinder into some spots. I used a smaller wire wheel attachment on a drill for other areas. Luckily I didn't get a flat tire. That rust corrosion required a lot of PB Blaster to loosen things up and get it out. The rear brake calipers look crusty, but seem to perform fine. I'll be replacing brake pads, disks and calipers all the way around later this summer for piece of mind.

Plastdipped the rear bumper that was silver to try it out.

Next week I'll install the 5100's, FJ coils and spacers. Then I'll be able to get into the other hard to reach areas and clean up.

I was just curious how bad other owners have had for rust on the East coast in comparison to my issues.