Well, I thought I'd stick my neck out and share what I've been working on.

This:

More coming...........

Roy

 

Plus this:

More coming............

Roy

 

Plus this:



Equals?

 

 

Build progress in an hour or two. I need to get my kid from camp.

Roy

 

I have been wanting to build an expedition-capable truck for a while. When we moved into a house with a garage, I had my project vehicle the same week. I started with an '89 4Runner with very little rust (for our area). 88,000 original miles. 22RE, Auto trans, A/C. I chose a first-gen because I like the smaller/narrower profile of this body style. I also had one when I was younger, so I get to re-live my childhood.

My tailgate was rusted out, and the rear window was broken. So ditching the top and gate wasn't a hard decision. I knew going in that the top would go. I found a beat up utility cap on eBay. The guy found it in the woods of a house he bought. I got it for a whopping $3, yes three. I did however have to drive over two hours to pick it up.

I started by dis-assembling the entire truck down to the frame. I thought this would be the best way to handle a 17-year-old truck. If I just start over, inspect, repair or replace, and paint every part for the assembly, I would have a truck that was like new.

Roy

 

 

The front crossmember was the only structural member that needed replaced. Everything else was stripped to bare metal and primed with RustBullet.

 

Here is where the server cabinet comes in. I was AMAZED how heavy-built this thing was. The panel above the bedside is the removable side-panel of the server cabinet. It is much heavier than regular sheet metal.

 

Other side. Notice the second fuel door pocket.

 

Here is the back, tack-welded. The rear doors were lengthened about 5". All the rear panel structure are parts of the server-rack framing. The Toyota body (length) itself was shortened about 5". Tail lights will be replaced with someting else.

 

Another view.

 

Inside view. Tons more storage capacity.

 

Headliner (interior) height has been raised a total of 15". Exterior height has been increased about 12". Truck will seat seven when I'm done. Back seats will be on the sides facing center. Everything is just mocked up and tack-welded right now. All seams will look factory when I'm done.

Rear, spare-tire crossmember was removed to make room for the aux fuel tank. I'm adding a 27-gallon fuel tank from a military Blazer. 44 gallons total.

Roy

 

I can imagine how freakin slow that's gonna be....will there also be space for storage and sleep space?

 

Interior will sleep three. There will be a fold out roof-rack that will support a 7' x 7' tent. There will also be a tremendous amout of storage, under the bench seats and in fold-down cabinets on the sides.

As to it being slow, a Mercedes turbo-diesel will take care of that. In the cab section of the roof-rack, there is a tip-up wind deflector to help a little with the wind drag.

 

im no engineer by anymeans, and you say the server doors are pretty thick, but if you are putting alot of weight up top and in the unfortunate incident of a roll are you going to be reinforcing the interior with any tubing? just from the picks it looks like it would buckle/crease easy. But other than that I think your project is bitchin'! and i cant wait to see the progress.

 

The new top and doors weigh almost exactly the same as the 4Runner top and that crazy-heavy tailgate.

Everything will be reinforced. Because of the nature of this build, I worked from the outside-in instead of the inside-out. Structural elements will be added when the exterior "skin" is completed, and the final design of the interior is decided.

Roy

 

Cool, I figured as much. As it definitely looks like you got things well under control, but ya never know.
What type of suspension and tires do you plan on running?
The turbo diesel sounds perfect.

 

Because my cargo weight will always be changing, I am planning on using the stock rear leafs with Firestone airbags. For the front suspension, I'm starting with the stock IFS. This truck needs to go thru a Maryland inspection, and they may fail a SAS. After the initial inspection, I can change it out. I'm not rock-crawling, and the front diff will stay open, so I may keep the IFS.

For the tires, I'm looking at Hi-Tech retreads in 31 x 10.5 x 15. I'll most likely add the crushed diamond to the retread package. I just need to check the load rating. The differentials have been cleaned, painted and new seals. I'm waiting to see how the turbo-diesel pulls with the stock 4:30's before I do any third member work and the locker. This may save me buying gears.

Roy