Operation Rebuild Chaos Edition

Operation Rebuild Chaos Edition Part 1

During my last Death Valley trip back in April 2007, my 4runner sustained heavy damages to an accident caused by driver error on all parties. Unfortunately the accident resulted in an inoperable 4runner and a heated debate on whether or not to repair or total it. After many months of discussion the decision to rebuild has now been set in place.

With the help of many friends and vendors the 4runner will be rebuilt better than version 1.0. The goal is to remove the entire engine sheet metal and replace it with a tubed front end which will be stronger and lighter. A new bumper will be designed in conjunction with the tubed front end.

Parts that I'll need to replace:
Hood - one with hood scoop will be nice
Headlamps - 2006+ would be nice
Radiator
A/C Condenser
Tranny Cooler
Power Steering Cooler - aftermarket
HID bulbs - So it'll be the same as it used to be
Air Box and tubing to throttle body
Misc other crap

I will probably keep my stock fan and not use an electric fan. Not sure but that's the plan as I don't want to incur additional costs on the repairs. Trying to keep the $$ down to a minimum since this is all out of pocket frown

Now to the good stuff. Pictures!



Here's what it looks like at home:



The first phase is to remove all parts inside the engine bay. Here's a shot of the passenger side after a bit of work.



Got most of the drivers side cleaned up as well as the front end but no pictures. I'll start to cut the sheet metal tomorrow and will keep all of ya posted on the ongoing results.
 

Operation Rebuild Chaos Edition Part 2

Here's some more pictures... the freaky stuff!





cuttin up the sheet metal was fun. didn't take much to really cut into the metal. now I just need to clean up the mess and start on the tubing work smile





thank you bob and sunny for dropping by to give me a hand smile tubing work will begin shortly. well as soon as I get all of the equipment/parts for em.
   

Operation Rebuild Chaos Edition Part 3

Man getting these tube bent and spot welding and attempting to level it is no fun. Now if I had the proper tools this would have been a piece of cake but what can I say, I love working hard on the easy stuff. With an extra set of hands the tubing was corrected. As for the bent tube for the passenger side, need not worry that was one of those "oops my bad" moments where I didn't calculate my bends correctly. Instead of starting with a new stick I just decided to use this one since the ends will get cut off. The ends will eventually be the point of reference for the top support on the bumper. This way the bumper is not only reinforced at the frame but also at the top to prevent snapping up like the last bumper.



Scab plates welded to the frame and then the tubes on to the plates. This way it's on there and won't come off (unless my welds are crappy). Tied them into the existing tubing work on the long travel kit. I guess this kit is a permanent thing now since I have no plans on going back now.



Test fit of the radiator to make sure it fits between the rails and also lining up the tabs for the mounts. The small tube across the front is for the condenser as they are mounted in the middle and top (strange that it's done this way and not at the top and bottom like the radiator.)

Thanks to Troy at Cal Mini Trucks (http://calminitruck.com/) who hooked me up with the new radiator and ac condenser. I was expected to pick up some used parts and he came thru with the new stuff smile LOVE IT! If any of ya guys are looking for any Toyota stuff, he's the guy to call. Very friendly and my gosh they got a ton of Toyota stuff! I was surprised to see so many Toyota parts there. It's Toyota heaven smile






Ahh the condenser is now mounted. Didn't get a chance to get the top but that'll happen next. A test mock up of the top tube to protect the radiator.. In case I decide to belly flop or something (you never know). Also to reinforce the front and strengthen it.






Some things to note: the frame ends has been cut off. It was so mangled that there was no hope in reusing it. Not that I would have anyway because I wanted to cut it so I have a better approach angle. The new bumper will be designed to wrap around the frame and also be supported by the upper tubes to box everything up. The front end will be very rigid and hopefully be able to survive anything that approaches smile

Design on the front bumper... tba.. but I'm running out of time. As for the hood/grill, headlamps and fenders, those will be mounted on a separate sub-tube frame that'll be attached to the body (by the firewall). The basic principal for this is because the body and the frame are two separate entities, if I were to make the front end rigid (fenders + frame) then something will give when the body flexes. So instead I'm going to have to setup a complex dual subframe setup in the engine area (one for the frame - as shown above) and another one just for the body panels. Should look slick when done but a whole heck of a lot of trail and errors!

Next up... tranny and power steering coolers. Instead of using the stock tranny cooler (which took a beating), I picked up the Hayden 678 cooler (the most commonly done mod). My aftermarket power steering cooler didn't survive either so the Hayden 678 will do too. Good thing the local shop had a few in stock. Looks like I've got a lot of work ahead of me.

This weekend will be building mounts for the tranny/steering coolers and also make a new dual battery tray. Somehow make some mounts to secure the big fuse box on the drivers side too. Once this is all completed I should be rocking and rolling. Just need to change out the belt and reconnect everything. Flush all fluids and do some maintenance. Hopefully it'll be up and running by mid next week.

Still pushing for the Pismo event but a lot of work to do. ugh!
   

Operation Rebuild Chaos Edition Part 4

Things we got done today:

  • Got the Toyota factory hood "temporarily" installed - I didn't realize that it's a factory hood that Troy at Cal Mini Trucks got me. Damn that guy just keeps on surprising me with the cool stuff he finds greengrin
  • Mounted the tranny cooler - Hayden 678 Cooler (Can't go wrong with this one)
  • Mounted the power steering cooler - Hayden 678 Cooler (shoot if it works for the tranny then it should also work for the power steering)
  • Battery tray cut out (still have to bend some parts and make it so it'll hold the battery but it's a start).
  • Fuse box mounts made (still need to make one additional top plate w/ welded nut)
  • Cut off front body mount so I can relocate it
  • Hood liner removed from damaged hood

Things to do for tomorrow:

  • I need to fix the darn tranny and power steering coolers as they are sitting too high and I don't like it. So I need to take those tacks off and redo em.
  • Finish the battery tray
  • Finish the fuse box mount
  • Begin building the air compressor mount
  • Figure out if I can install the hood latch somehow.

Other pending items...

  • reinstall hood liner
  • remove and reinstall wiper washer lines
  • air box
  • reconnect all wiring
  • build power steering reservoir mount
  • build radiator fluid overflow container mount
  • build washer fluid mount
  • flush all fluids and do basic maintenance
  • install new belt
  • build sub frame for headlamp and fenders
  • build front bumper
  • charge a/c
  • paint hood?
  • prob some other stuff I'm forgetting

enjoy the pix clap









Things I found in my wreckage trash bag. lots of busted and trashed item but one of my Lightforce 240 XGT housing survived smile The mount was toast but the other Lightforce had a damaged housing and a good mount so now I've got one good 240 XGT!!! yay! Also one of the 170's survived too smile looks like I've got a lop sided lamp setup haha.
   

Operation Rebuild Chaos Edition Part 5

Sorry no pics. Maybe tomorrow when I get some more support. Bob, Bruce and Sunny will be dropping by to lend a hand smile woo hoo!

Things I got done today:

    * Remounted tranny and power steering cooler
    * Welded up battery tray
    * Air Compressor plate made and mounted to the engine tube frame
    * Began rebuilding tire carrier for rear bumper.

Things to do for tomorrow:

    * Weld fuse box mount
    * Build mounts/tab for air box
    * Mount battery tray
    * reinstall hood liner
    * remove and reinstall wiper washer lines
    * build power steering reservoir mount
    * build radiator fluid overflow container mount
    * build washer fluid mount

Other pending items...

    * build sub frame for headlamp and fenders
    * build front bumper
    * buy used air box
    * buy used headlamps (06+)
    * buy hood pin locks
    * buy new belt
    * buy fluids
    * reconnect all wiring
    * flush all fluids and do basic maintenance
    * install new belt
    * charge a/c
    * paint hood?
    * prob some other stuff I'm forgetting

Coming along nicely. Tomorrow will be big as we'll have most of the parts reinstalled back in the engine bay. It'll actually look more like something rather than a hunk of junk  chair Hopefully we'll be able to fire her up next weekend after doing the basic maintenance stuff.
   

Operation Rebuild Chaos Edition Part 6

Things I got done today:

    * Remounted tranny and power steering cooler (again - the damn hood was hitting it and definitely wasn't gonna look good lining up the fenders)
    * Welded up battery tray (again - the dual tray was a no go as there was no room. So I ended up cutting it in half and making two.)
    * Welded fuse box mount.
    * Built tab mounts for air box but it sat too low so when the tire is at full compression would smack it. Cut it off and have to figure something else out. Really don't want to use an aftermarket air box but the darn factory one is pretty ginormous.
    * Body mount relocated (tack welded)
    * Driver side subframe tack welded to relocated body mount
    * New subframe now features driver side headlamp!!!!
    * Reinforced subframe (all tack welded for now)

Things to do for this week:

    * Build passenger side subframe
    * Reinforce fuse box by adding another "L" bracket
    * add another mount for driver side headlamp
    * Build mounts/tab for air box
    * Mount battery tray
    * reinstall hood liner
    * remove and reinstall wiper washer lines
    * build power steering reservoir mount (use big hose clamp style design somehow)
    * build radiator fluid overflow container mount
    * build washer fluid mount

Other pending items...

    * build front bumper
    * buy used fan clutch
    * buy used air box
    * buy used headlamps (06+)
    * buy hood pin locks
    * buy new belt
    * buy fluids
    * reconnect all wiring
    * flush all fluids and do basic maintenance
    * install new belt
    * charge a/c
    * paint hood?
    * prob some other stuff I'm forgetting

When I get pics of the driver side subframe section that'll really look cool. Got the hood lined up with the fenders to make sure it lines up perfectly and also got to install the driver side headlamp!! So right now I have one side pretty much done. All I need to do is weld her up and then reinstall the fender and the driver side looks like it's back to normal. smile Pics in the morning  clap Bruce said that I've got a lot of work to do and getting it done in 2 weekends may be a challenge spank Guess I'm gonna have to work double time now confused

In the process of moving the A/C lines I may have inadvertently kinked the high pressure line. Not sure but I'm hoping this is not the case. If not I guess I'll have to figure out a way to replace it cuz I definitely need my A/C tapedshut Good thing I really don't need it right now!
   

Operation Rebuild Chaos Edition Part 7

Doesn't this look sexy!  tapedshut



Two tubes from the side are triangulated for strength and support. This these tubes will support the fenders, lights and hood I needed to make sure it's strong enough to support the weight.



The next two photos show the use of the stock body mount. I ended up cutting it from the frame and relocating it higher by the lights. I made two mounts that holds two tubes to traiangulate the headlamp assembly. The top tube is a single bend to follow the lines of the headlamp and is attached at the back half of the firewall and the front body mount.





Doh the passenger side is bare! hopefully this side will look like the drivers side soon.



the rain from a few days ago did a quick number spank Hopefully I'll have it up and running shortly.
   

Operation Rebuild Chaos Edition Part 8

I got a bit of work done this morning. Or actually more like 10000 steps back. I ended up removing the mount for the air compressor. Steve (robinhood4x4) recommended that I mount it horizontally with two reinforced supports instead of the one shown above. He said over time the vibration will do a number on it so instead of waiting for it to fail I just got up early this morning to cut/grind/clean it all off. Guess I've got more work to do tapedshut

Also removed the clutch fan to get a replacement one. Man these things are a PITA to remove! Anyway I hit my usual junkyard guy (Toy @ Calif Mini) but he couldn't source a clutch fan or the headlamp so he referred me to K & P Auto Dismantlers in Fontana, CA. Picked up a clutch fan and a drivers side headlamp smile

All I need to do is pick up a passenger side headlamp that I have saved (later this week). Placed an order with Evan @ Northridge Toyota for some Toyota Red (coolant), belt and some misc smaller items and hope to reassemble everything this weekend smile
   

Operation Rebuild Chaos Edition Part 9

Wish I got more done today but I ran out of gas and had to scramble to find someone local that was open late frown  No pics but I'll make sure to take some tomorrow. Hopefully by tomorrow I'll have most of this done so I can start painting to tubes and begin reinstalling everything. (very optimistic but heck I'm running outta time!) chair

Things I bought this week:

    * Belt
    * Tranny oil
    * Toyota red coolant
    * Air filter
    * Both headlamps
    * Fan clutch

Things I got done today:

    * Driver side battery tray mounts made and welded to the tray.
    * Passenger side subframe tack welded - lights installed for inspection.
    * Drive side subframe reinforced with gussets. (almost fully welded - a few places are still tacked on)
    * Cut 35"x12" base plate for front bumper.

Things I need to do tomorrow:

    * Reinforce fuse box by adding another "L" bracket
    * Add another mount for driver side headlamp
    * Add another mount for passenger side headlamp   
    * Weld driver side battery tray
    * Weld top cross member (underside)
    * Cut plates for front bumper
    * Build mounts/tab for air box
    * Build mounts for passenger side battery tray
    * reinstall hood liner
    * remove and reinstall wiper washer lines

Things to do for this week:

    * Build mounts for air compressor
    * build power steering reservoir mount (use big hose clamp style design somehow)
    * build radiator fluid overflow container mount
    * build washer fluid mount

Other pending items...

    * make fastener mounts for fenders
    * build front bumper (bend tubes)
    * buy hood pin locks
    * reconnect all wiring
    * flush all fluids and do basic maintenance
    * install new belt
    * charge a/c
    * paint hood?
    * prob some other stuff I'm forgetting

gf's response so far on my quest to rebuild the 4runner. "either sell it or junk it!"  tapedshut

Adrian, thanks smile I really don't have skills. This is all the beautiful work of a program called Photoshop angel
   

Operation Rebuild Chaos Edition Part 10

Here's the finished project of the headlamp assembly. I finished welding everything up and this is how it turned out. It's slightly angled on the ends up that's because it's being held by vice and c clamps until I finish welding it to the body. Once it's fully welded to the body it'll be straight.



Another angle showing the lamps. You'll notice the front bumper in this pic. Hard to see but it's sleeved and plated (tacked on for now).



The pain in the rear headlamp assembly. Not fun trying to make everything line up with the hood, lamp and fender.



The body mount was used to support the sub structure for the hood, lamp and fenders.



Last pic of the lamp subframe to give you an idea of what it looks like.



Things I got done today:

    * Reinforced fuse box by adding another "L" bracket
    * Front bumper base plate and sidewalls bent/welded
    * Welded top cross member (underside)
    * Welded both driver and passenger side headlamp

Things to do for this week:

    * Bend tubes for front bumper and weld bumper
    * Strip rust build up on headlamp assembly, primer and paint prior to installation
    * Add another mount for driver side headlamp
    * Add another mount for passenger side headlamp   
    * Weld driver side battery tray
    * Build mounts/tab for air box
    * Build mounts for passenger side battery tray
    * reinstall hood liner
    * remove and reinstall wiper washer lines
    * Build mounts for air compressor
    * build power steering reservoir mount (use big hose clamp style design somehow)
    * build radiator fluid overflow container mount
    * build washer fluid mount

Other pending items...

    * make fastener mounts for fenders
    * buy hood pin locks
    * reconnect all wiring
    * flush all fluids and do basic maintenance
    * install new belt
    * charge a/c

A long way to go but I'm going to be trying to do some stuff in the morning before work so we'll see how this all works out. I have one full weekend left to get the misc stuff done so hopefully I'll be able to begin painting the tubes during the week.
   

Operation Rebuild Chaos Edition Part 11

A lot of thought went into this design, with the help of Bruce and also the WWW. Gotta love finding others that have done something similar to give me a better vision of how to complete this job. I ultimately used two different tube frame configurations around the engine bay.

1. Using 1.5" tubing I reinforced the engine bay by having a very rigid system where the radiator, a/c condenser, tranny and power steering coolers, batteries and other engine related components are tied together. This way the vehicle can run as is without anything else such as the hood, fenders, etc. I also triangulated everything around the top as the front bumper will also be attached at the top. I did this by design so that if I were to get into another accident, the front bumper will not buckle and cave it like it did on the last design. (the concept is like a double sheer design for the most part) By having two rigid points (one at the top and one at the bottom) the bumper will definitely be more securely attached and distribute the forces. Now if I get into a really bad wreck I'm sure the frame will give cuz something will. (or my welds will crack if my welds were done crappy! chair )

2. Since the 4runner is a body on frame configuration, I didn't want to attach the fenders, hood and headlamps to the rigid 1.5" tubing frame. This is because the front will now become rigid and the rest of the cab will definitely get affected as the body will flex on and off the trails. So I had to get creative and designs a lighter duty subframe (0.75" tubing) around the engine bay to accommodate for the fenders, hood and headlamps. I cut off the bottom of the front body mount and used that mount along with the rubber bushing by relocating it higher where I wanted to place it. By having a secondary subframe for the body panel items this keeps the frame and the body separate and maintain the same rigid setup that comes from the factory. If you look closely at the smaller tube subframe with the lights, you'll notice that I incorporated a "L" bracket that will be welded to the firewall of the cab. I used a large piece to ensure that it is distributed so nothing will prematurely fail since the sheet metal is rather thin in comparison to the bracket.

The main tube configuration is setup to go through the "rigors" of offroading. If you look at some of the extreme offroading vehicles, their entire setup is tubed (with hardly any sheet metal) so the concept is the same. The only difference is that I've just added tubing to the existing frame. Basically reinforced it and made it stronger for the most part. I highly doubt the engine tubing/frame will get damaged now that it's really boxed up. Of course anything is possible so I won't say it's 100% bullet proof but it's much stronger than it was before.

Didn't get to work on it this morning (had an all nighter project to get done for work frown ). Maybe tomorrow morning if I can get up early enough!
   

Operation Rebuild Chaos Edition Part 12

this weekend has been a really frustrating weekend. in the hopes of getting both fenders reattached I ran into some serious issues as nothing really wanted to line up. This forced me to cut and start over on a lot of the parts frown Anyway finally got some progress today and man I'm serious running out of time!

Things I got done this week/weekend:

    * Purchased hood pin locks
    * Purchased fasteners for fenders
    * Purchased shackle hangers for recovery point - front bumper
    * Welded driver side battery tray
    * Built mounts and welded air box
    * Built mounts and welded air compressor tray
    * Built and welded modified second battery tray
    * Welded fasteners for passenger side fender
    * Passenger side fender reattached
    * Redid mounts for condenser as the connection hose hit the radiator mount - serves me right for now checking the lines when attaching these suckers.

Things to do for this week:

    * Build fender mounts for driver side fender
    * Reattach driver side fender
    * Build power steering reservoir mount (use big hose clamp style design somehow)
    * Build radiator fluid overflow container mount
    * Build washer fluid mount
    * Add another mount for driver side headlamp
    * Add another mount for passenger side headlamp   
    * Bend tubes for front bumper and weld bumper
    * Reinstall hood liner
    * Remove and reinstall wiper washer lines
    * PAINT!
    * Reconnect all wiring
    * Flush all fluids and do basic maintenance
    * Install new belt
    * Charge a/c (maybe if I have time)
    * Reattach rear bumper and modify the tire carrier if I have time.

Sorry no pictures. Maybe tomorrow. Just a bit pissed and frustrated because I didn't get as much done as I wanted to. Bob, thanks for helping me out with building the fasteners tabs and with the second set of hands holding the fender.

Note: the passenger side is complete and looks nice but some areas has some severe gaps on the fender. Going to have to redo the fiberglass after the Pismo event to make it cleaner and flow with the lines better. It works for now but it's definitely ugly frown