This is our modo for the build!

 

Progress last week. The floor pan is for the most part set where it needs to be. We are not going to weld it in place until we have the dash and steering column in place due to the rest of the stuff needing to line up with everything. We cut the driver's side dash support bar off from the 91 and the mounting plate from the 97 (the passengers side lined up bolt wise). And then welded the 91 end onto the 97 bar so it bolts right in place.

 

'scribed. nice! get some custom tags for it: "91 & 97"

 

So we have a delema which someone with experience with body lifts might be able to help with. As you can see in the second picture above, the 4wd shifter needs to be extended so it will not interfear with the body. Is there a fix for this? Thanks

 

i saw shifter extensions somewhere today (can't remember what site, i can look it up tomorrow if you want). nothing more than a piece of tube with a threaded hole on one end and threaded rod on the other, maybe about 6"-8" long

 

either cut and dog leg the shifter, or (the easy way) trim the floorpan... if you have a cactory center console, it'll cover up the minor cutting your gonna have to do...

 

Cool, Thanks I'll look them up. Of course it's that easy. :-)

 

This is a great build!! Subscribed!!

 

That support you spliced is more then a dash support for the dash to bolt to.
It's also a body stiffener.
Did you just cut and butt weld them together or did you sleeve it any for extra strength? I'd sleeve it a few inches on each side of that weld. Just in case.
But that's just me.

4Crawler sells shifter extensions.
http://www.4crawler.com/4x4/ForSale/...lTransmissions


Nice build so far. I'm not a fan of that 3" body lift but it ain't my truck
Your friend will be a lot happier with the 3rd gen suspension. Not only for comfort and flex, but also for ease of modification compared to the second gens.


EDIT: Also, heres an 87--00 4Runner swap.
http://www.irbisoffroad.com/project4.asp
(click that main pic there for more pics).

 

thanks scuba. yeah, those are the ones i found

 

Thanks we ended up getting a 3" extention which fit perfectly. We haven't had time to work on it over the past two weeks but hopefully next week the rain will clear out and we can get some more progress.

I haven't posted updates for awhile. We ended up cutting the firewall off of the 97 floorpan and just using the original 91 firewall with some mods. There is a seem at the bottom of the firewall where the firewall and floorpan meet on both bodies. We just lined up the seem from the 91 and the 97 and the shift linkage and everything there lined up without needing any extentions or moding. So the floorpan is almost all the way in (we ran out of welding wire).

 

We actually had to move the hole for the fresh air intake beneath the windshield wiper tunnel. That was accomplished by transplanting the 97 section of that area over to the 91 body.

1st picture is the hole cut out.


2nd 97 sheetmetal attached to the airbox.


3rd sheetmetal tacked into place.

 

A little more progress last week. The inner area of the floorpan is finished. We are going to lift the body back off and weld in some additional supports on the under side. It's part of the "over build it" plan.

 

The firewall is almost complete, we just need to drill and open up the hole for the condensation and A/C lines. After welding everything in place we put an extra sealant over the welds.

 

Sweet first 91 to 97 swap and good to know someone else here is from sac. Hope everything goes smooth from here.

 

Well it's been a little while since I posted any updates but we have been making progress. The floorpan and firewall were very time consuming, remember the entire dash and HVAC system from the 97 is going in.

The floorpan was sealed and painted with epoxy paint to get it all protected.

Floorpan finished:

 

Bottom sealed and undercoated.

 

Wiring in and dash test fit for the first time.

 

Well today was a great milestone in the build. We started it and it ran great!



And we finished the install of the dashboard.



Here is the video:

http://www.youtube.com/watch?v=gNZOskFgQ48

 

Nice. Good to see it runnin and good work on it so far