Topic: Steel City Racing & Marlin Crawler: KOH 2019 Toyota 4Runner IFS 4600 Build

[Charles4x4]

With school back in full swing here and work ramping up, my daily work sessions are starting later and later - given less traffic in the build thread, I don't think I'm the only one who is just busier!

Anyway, I stayed up till 11 last night and missed the first College Football Game of the season to get the new Aeromotive Phantom Stealth 200 system installed in the Jaz Pro Sport II cell.  I also installed the Classic Instruments fuel level sender at the same time (which is missing hardware - so I'm off to get nuts/bolts/washers again today). 

Nothing hardcore - pretty straight forward.  The pics tell the story:



The Internals:


Drilling Pilot Holes (through both the lid and cell):




Smaller holes for inner diameter of components:




Larger holes for outer diameter of components:




Checking fitment:


Done:

[superyota]

Looks good!  Keep it up!

[Charles4x4 [OP]]

This week I've been focused mostly on wrapping up the fuel cell and plumbing.  Earlier today, I was able to fire it up for the first time in weeks. 

Short Video:
https://www.facebook.com/SteelCityRacing4x4/videos/321765038597631/

The fuel system works flawlessly - Aeromotive, Jaz, and Russell are top notch!  I still have to secure the lines/wiring for the drive to CA, but zero leaks and zero problems!  Not bad for my first fuel cell plumbing install.



The lines run along the top of the frame, into the cab where I reused the rubber entry for the old fuel system wiring to ensure a snug and abrasion free entry, and into the cab.  It connects to the Aeromotive Phantom Stealth 200 kit on the Jaz Pro Sport II cell.  While there are two filters in the tank, I also installed a 10m filter on the supply line just before the Fuel Pressure Gauge port.



For the fuel vent line, it has a roll-over check valve (meets KOH Rules) and routes to the side, up, over, down, and back to the center.  It then ties into the OEM fuel line vent system underneath including the old catchment system (meets KOH Rules).

I still have to finish wiring the new level sender to the gauge, but I'm calling the fuel system mostly done at this point!

While I was wiring, I went ahead and installed the Rear LED Amber/Red/White Race light.  I attached it to the bottom of the spoiler with a lot of hardware.  It feels strong.




There are a ton of pattern options you can select on the toggle switch where the Amber flashes differently and the Red is mostly just on.  I then wired the center white LED to a toggle switch on the dash.


Other Updates:
- The 3.8 Atlas II is done and paid for.  It'll be shipped out this week.

- I went ahead and ordered my Comms and Intercom from Rugged Radios while they had their Labor Day 20% off sale.  I opted for their Race Ready 2-Car 6100 system with radio/intercom wiring harnesses.

- I mailed in my template on the race window nets to PRP.  We'll have mesh with 1" webbing at 8" increments, a spring rod at the top and metal rod at the bottom, and 12 grommets to make sure it is tight.

- I started on the new Master Kill Switch, but still have work to do.  I also have some ideas on the secondary latches for the front doors.  I hope to have it done by the end of the week.

I also shipped a ton of stuff back that didn't fit and bought more stuff that hopefully will - it's time consuming, but thank goodness for Free Returns!

More updates coming soon.

[:)bestgen4runner]

 "I still have to secure the lines/wiring for the drive to CA"
Driving it to the race? no trailer and tow vehicle?

[Rockcrawlintoy]

"I still have to secure the lines/wiring for the drive to CA"
Driving it to the race? no trailer and tow vehicle?

He is driving it to cali for fab work and suspension work.

[Toyotadon]

I would not trust that spoiler to hold up to KOH.  It's mostly plastic, with only a few small bolts at each end.

My opinion would be to mount the rear light to the roof structure inside the rear hatch. You won't have glass in there anyway, so it should work just as well. You may even end up with it mounted to the cage once that's done.

[Rockcrawlintoy]

I would not trust that spoiler to hold up to KOH.  It's mostly plastic, with only a few small bolts at each end.

My opinion would be to mount the rear light to the roof structure inside the rear hatch. You won't have glass in there anyway, so it should work just as well. You may even end up with it mounted to the cage once that's done.

I would agree. that spoiler is gonna get a work out with that light on there. I would also install inside on the cage

[Charles4x4 [OP]]

I would not trust that spoiler to hold up to KOH.  It's mostly plastic, with only a few small bolts at each end.

My opinion would be to mount the rear light to the roof structure inside the rear hatch. You won't have glass in there anyway, so it should work just as well. You may even end up with it mounted to the cage once that's done.

I would agree. that spoiler is gonna get a work out with that light on there. I would also install inside on the cage

Tha's what I was thinking, but once I put stronger bolts with washers/lock washers on the sides, it ended up really sturdy.  It has internal clips that hold it from coming out and the bolts lock it to the clips.  It'd take a ton of force to get it to come off...but KOH may still do it.  Note the light bar is extremely light, so the entire setup is ~5lbs or so max.

If it flies off in testing at JV, we'll pull it and mount on the cage.  For now, it's surprisingly sturdy.

[Rockcrawlintoy]

Tha's what I was thinking, but once I put stronger bolts with washers/lock washers on the sides, it ended up really sturdy.  It has internal clips that hold it from coming out and the bolts lock it to the clips.  It'd take a ton of force to get it to come off...but KOH may still do it.  Note the light bar is extremely light, so the entire setup is ~5lbs or so max.

If it flies off in testing at JV, we'll pull it and mount on the cage.  For now, it's surprisingly sturdy.

Also in the unlikely event you flop the spoiler may break as well.

[Charles4x4 [OP]]

Also in the unlikely event you flop the spoiler may break as well.

As long as the spoiler protects the light bar (per KOH Rules), we're good.  The spoiler actually came off a vehicle that flopped on its top, so it's already been through that once and only a small crack on one side resulted.  So it's a bet "tested" at this point.

With all that said, it's plastic, so who knows.  But we'll find out in testing - I can practically hang on it now.

[Charles4x4 [OP]]

We got most of the Master Kill Switch wired last night - my awesome wife stayed in the garage till 11:30 to help pull wires, crimp, heat shrink, etc.  We ended up missing the entire Falcons/Eagles game, but o-well. 

With the flip of a switch, we will now simultaneously kill the Battery, Alternator, and Fuel Pump - surely this will finally shut the v8 down!

We ran out of 2ga wire before we could make the final connection - OEM Alternator Out Wire to the Bus.  I'll close it out and test everything today.

Alternator Out Connector to Switch Input 1:


Battery + to Switch Input 2:


Wiring runs through firewall:


And into the cab:


To the Switch that is now securely mounted where the old Ash Tray plastic thing used to be:


Switch Output goes back through firewall to power a 4 Prong Bus. Dist. Block, Fuel Pump Power, and Wire that connects back to OEM Alternator Out Wire (not yet connected as I ran out of 2ga wire) connected to remaining 3 prongs on Bus:


I crimped all 2ga wire and used heat shrink.  I still need to re-do some OEM wires (Dist. Block, for example) that need to be heat shrinked.


Once I get 10' more of 2ga wire, I'll make the final connection from Bus to OEM Alternator Out Wire - this will flow through the OEM Alternator wiring and connect straight to the Battery + for normal charging.

I'll then test to make sure it all works as planned, shore up a few OEM connections, and zip-tie everything.

[Charles4x4 [OP]]

Master Kill Switch is finally done!  We studied the diagram again and saw that current can flow both ways when in 1+2 mode, so no need for the final wire.

Simple Battery Connector:


Bus with Switch Output, Factory Wires (2), and Fuel Pump:


1+2 - Running Mode:



OFF - Kill Mode:



Wiring Diagram on Blue Sea switch:


For what is so simple in concept, this project was harder than expected on a new gen vehicle.

Done and Moving On.

[superyota]

Can't wait to see this thing in person. 

[Charles4x4 [OP]]

Another update.  All small stuff:
- Got the "Drivers Assist" camera wired up and mounted.  We may move it to the front bumper later:




- Ran out of gas on the way to the station and was able to coast in.  I got a few weird looks:




- Ran out of wiring and connectors again, so had to replinish.  Also broke my HF Multimeter, so I upgraded:


- Got the Fuel Gauge and Fuel Level Sender wrapped up:








- After swapping out a faulty AEM Fuel Pressure Gauge, all fuel related gauges are done.  Truck reads 14.5 AFR and 49 PSI at standard conditions.  AFR dropps to 11-13.5 when above 4K RPM, but we should be able to fix it when we do the MAF Calibrator later this week:


- All our Communications and Intercom equipment arrived from Rugged Radios.  Will be installing later this week:


- Almost done with all the small stuff I can knock out before CA:

[Charles4x4 [OP]]

I'm also excited to finally announce that 4x4Labs will be partnering with Steel City Racing on this KOH build. 4x4Labs will be building our Front and Rear Bumpers, Sliders, and Skid Plates - all designed and engineered for maximum strength and clearance while minimizing weight.

Luke and his team are the best in the business and the new products & enhancements designed for this build and KOH will be integrated into future 4Runner armor offerings by 4x4Labs.

In order to keep our timeline on track, the trip out to CA is now being moved back up to late-September as originally planned!  The truck will be with Luke, HD, and the 4x4Labs team starting the week of 9/24 for 3-weeks for the bumpers, sliders, and skid plates to be engineered and installed - it'll be tight, but Luke's '06 4th Gen V8 will be used for mock-up until mine arrives.

Once 4x4Labs is done, Luke has graciously agreed to drive it to Marlin for me. Once BigMike is done with his work, it'll head to RockSolidToys and then may head back to 4x4Labs to finish up the skids with the 4 Link and Atlas II completed.

Thanks again to Luke, HD, and the amazing team at 4x4Labs (www.4x4Labs.com).

[Charles4x4 [OP]]

Check out what just arrived!  The 3.8 Atlas II could very well be the difference maker for our 2019 KOH.  Special thanks to Steve and Cole at Advance Adapters for sponsoring our build and believing in our team.

Can't wait to get this in Wyatt at RockSolidToys' hands for the install along with his rear 4-Link!







Along with everything we need for the install to the Toyota A750F:


Given the lead-time on the Atlas II, I'm really glad to have this one in hand and ready to ride backseat on the trip out to CA in a few weeks!

[Charles4x4 [OP]]

Another update:
- We finished tuning via the URD MAF Calibrator.  Unfortunately URD doesn't have a map for AFE Intake on a 4.7L V8 and didn't offer to create one for us, so we had to do it manually. 

It was harder than we were thinking - me driving 0-60 mph runs, a friend in the passenger seat reading AFR at various RPMs, and a third friend in the back with the laptop tweaking things and re-uploading a new tune ever 2-3 mins.  It took us well over an hour, but we got AFR around 14.5 <4K RMP (no adjustments to stock needed) and 13.5 >4K RPMs (adjustments to stock needed here) and decided not to push our luck any more.  Very thankful we didn't get a ticket or stopped in the process - doing 60 in a 30 isn't easy to pull off.





- Also got the Rugged Radios 6100 Race Ready kit installed.  We gutted everything we didn't need on the center console except for the structural parts and used it to mount the radio, intercom, and toggle switches.  Now all we have to do is hook to our helmets, flip a switch, stick the antenna on, and we're ready to go.





- We also finished the secondary locks per KOH rules.  Nothing pretty, but they are spring loaded for a quick lock and just plain work.  Took a lot of adjustments to get these to lock/unlock easily without space in between.









- Our PRP Safety Nets are almost done.  They won't make it to AL in time, so they're being shipped to Luke at 4x4Labs' shop.

- I'm also waiting for the Denso Alternator and Rugged Radios Dual Pumper to arrive later this week.  Once they are done, I'll check all fluids and be ready for the drive out to CA this coming weekend.  36-Hr Trip!

[Charles4x4 [OP]]

Another Quick Update before I start the 36-hr drive to CA this weekend:
- New Denso Alternator arrived.  I tried all sorts of methods to get it out and eventually found a "quick replacement" route that should allow me to swap it in 20-30 mins just in case we have to during the race.





- The old Alternator with 100K Miles on it:


- Also got the new Rugged Radios M3 Two Person Air Pumper system in.  I'll be wiring the switch in today and will actually install the pumper to the cage in CA.



I'll be posting some live progress pics from the drive to CA on social media if anyone is following us there.  Be praying the drive out is seamless and we make it in record time!

Have a great weekend everyone!

[:)bestgen4runner]

Tell us about that Sexy 1st gen in the back ground?
Hey there good looking. 

[Charles4x4 [OP]]

Tell us about that Sexy 1st gen in the back ground?
Hey there good looking. 

Thanks - it's my DD.  I love 1st Gens.  More details than you could possibly want to know here:
https://www.yotatech.com/forums/f116/87-turbo-restoration-build-304774/

[Charles4x4 [OP]]

Rugged Radios M3 Dual Air Pumper is installed.  I just have to mount the actual unit to the cage in CA, plug in one connector, and go.



All that's left is packing up and leaving.

[Charles4x4 [OP]]

I ended up leaving around 11:30 CT on Sunday to head out on the long drive.  For those not following FB or IG and haven't been receiving the real-time updates, as of 9am PT this morning (Wed), the truck is now in Luke and HD's capable hands at 4x4Labs in Grass Valley, CA.

I'm sure many followers are waiting for a long story filled with uncertainty from attempting to drive a KOH bound rig 36-hrs and 2,400 miles across the country.  Well, there wasn't much.  I literally did not have a single problem the entire trip.  The rig is rock solid reliable from an Engine, Transmission, Electrical, and Fuel Delivery standpoint.

I averaged 12-hrs a day only stopping for gas and meals.  I put air in the tires a couple times.  I checked fluids each morning.  I monitored Fuel Pressure, Engine Temp, and AFR every few minutes.  And I mostly watched the fuel gauge.  I was able to get 15-18 MPG between stops and rarely could make it till 1/4 tank before I simply had to step out and stretch my legs.


The only eventful thing happened on Day 1 where I intentionally ran the gas to 1/16 Tank to find true Empty.  It ran great until I went down a steep hill, at which point all the fuel shifted to the front of the cell away from the pump pick-up and the engine died.  I threw it in N, coasted down the hill, and fired it back up as soon as I hit the next climb.  It died again on the next downhill, but I was able to coast a couple miles in N to a an exit where I ran a stop sign at the bottom of a off ramp and coasted up next to a pump with 0 inches to spare.

After that I never let it get below 1/8 of a tank just in case.

The rest of the trip consisted of driving, eating, filling up with gas, stretching legs, and driving more.  The scenery changed enough to keep things interesting the first two days.  But once I got past Bonneville in Utah, it got a bit too repetitive - especially in Northern Nevada.


Tons of scenery pics from the trip are on FB and IG.  Here are a few of my favorites:


Cheyenne, WY:


Green River, WY:


Bonneville, UT


Tahoe National Forest, CA:

[Charles4x4 [OP]]

This morning I got to spend some time with Luke, HD, and the 4x4Labs team at their new, huge shop in Grass Valley, CA.  It's impressivet!



Luke and the team have been building 4x4 Armor for close to 20-years and their products are world class for strength, functionality, and design.  They take the approach of allowing their products and reputation to speak for itself - and the pride they have in their craftsmanship and passion they have for the offroad industry shines through in the end product.



Their shop is a mix of Hi-Tech equipment and HUGE old machinery.  There is also a massive powdercoating booth and oven - they do everything in house!  They have a flow throughout the shop - not a lot of talking, but a ton of work getting done.  Behind the shop is at least 1 of every 4x4 Toyota made since the 1st gen pickup for mock-up including tons of Land Cruisers, Tacomas, and Pickups.









They still do a ton of 80 Series Land Cruiser stuff, but see the 3rd, 4th, and 5th Gen 4Runner platforms ramping up dramatically.  Our KOH build will augment their large offering with a Complete System of 4th Gen 4Runner Armor that will be integrated together in fit, functionality, and style!

[Charles4x4 [OP]]

For our 4th Gen, Luke and the team will be creating a light weight, extremely strong, high clearance Front Bumper that will be similar in style to the one shown on this GX below and will house our Warn Zeon Platinum 10-S winch and a LED light bar.

This one was still being fabricated while I was there and will still missing a few components including the upper bar in front of the grill (on the floor to the left):


The Rear Bumper will be similar to their existing 4th Gen 4Runner rear bumper and the one shown on this GX.  They have 3 or 4 ideas to enhance it to make sure it has maximum clearance and strength while protecting the body and saving weight.  This bumper has the best departure angle of any on the market.  It'll be made to hold a tire carrier and ladder system in the future, but of course we won't run anything except the bumper to save weight for KOH:




The sliders will be similar to the one pictured below including the slide plates and kick-out at the rear, which will fit our 3" extended on each side Currie RJ60 in the rear.  They have some weight saving ideas here too:


And finally, they'll be fabricating a full skid plate system for the undercarriage that will be made out of high strength steel for maximum durability as we drag the 4Runner over obstacles at KOH.

I'm really excited to have Luke, HD, and the 4x4Labs team partnering with us on this car.  Their passion is evident in their products.  No flashy marketing, no gimmics.  Just solid products for those who want maximum protection and performance with top notch design.

Before I left, I handed them the keys and challenged them to work their magic and simply have fun with it.  I know they'll do an amazing job and I cannot wait to see the full system of 4th Gen 4Runner armor that will be turning heads when they are done!


Thanks again for the 4x4Labs team for partnering with us on this build and being such wonderful hosts while I was in CA.

Once Luke is done, he'll be driving it to BigMike here at MarlinCrawler for the next phase of the build in mid-October.

[Charles4x4 [OP]]

Catching up on posts here.  The forum was down some the past few weeks so a few of these are old:

Got some great updates from Luke and the team at 4x4Labs last night:

- Luke finished his new 4th Gen 4Runner prototype front bumper on his own rig and will be completing a slightly improved and jig-built version for mine next. 

- This new 4x4Labs 4th Gen 4Runner bumper is designed for Ultra High Clearance, Maximum Approach Angle, and a No Fluff Design. Just Strong, Sexy Lines, Low Weight, and Maximum Protection.  What else could you ask for!

Here are a few pics of the prototype:






- Check out the Approach Angle - Insane!




More details of the design and construction.  Sexy welds!








- In order to ensure maximum approach angle on the front bumper, they relocated our PS Cooler and added a high performance aluminum cooler.

I can't wait to see the bumper finished, powder coated, and stamped with the 4x4Labs brand on our KOH rig.  More magic to come from 4x4Labs over the coming days!

[Charles4x4 [OP]]

One final update for the day.  I have been working on sequencing with Luke, BigMike, and Wyatt.  Here's the latest on the timeline:

- Oct 19: Car goes from 4x4Labs to Marlin Crawler

- Nov 5: Car goes from Marlin Crawler to RockSolidToys

- Dec 3: Car is pretty much done and ready for testing

Moving 4x4Labs up to the front of the CA work ended up helping us get back on track with the timeline.  We're all feeling pretty good.

I won't spoil the surprises, but a lot has been accomplished on the front suspension and steering over the past few weeks. 

Also, Front Gen 2 RCVs have also been received!  I'll post pics when I have them.

[Charles4x4 [OP]]

Quick Update:
I'm waiting for some updated pics to arrive from both 4x4Labs and Marlin Crawler. A ton of work done on the car over the past 2-weeks, but not many pics to show for it. I expect a ton of pics to arrive at the end of the week when the car moves from 4x4Labs to Marlin's shop.

Some Details:
- Armor will be done by Friday and 4x4Labs had a great idea for the Rear Bumper that I'll show off soon.

- Front Suspension and Steering are in process. The UCAs, LCAs, and Spindles are being laser cut this week.

- We're also taking final measurements off the new Gen 2 RCVs in the front to make sure everything will match perfectly.

- We've also been coordinating heavily with Icon on Front Coilovers, Rear Shocks, and Rear Coils.

- And Wyatt has some radical ideas for the rear 4-Link that we'll go into soon as well.

I'll post another update as soon as the pics begin to arrive.

[Charles4x4 [OP]]

Got a few "In Process" pics from Luke at 4x4Labs last night.  These are from earlier in the week.  All armor (Front Bumper, Rear Bumper, Sliders, and Skid Plates) will be finished, powder coated, and badged by EOB Tomorrow.  Then Luke is personally delivering the car to BigMike at Marlin Crawler for the next stage of fabrication.

Luke surprised us by building all armor (Front/Rear Bumpers, Sliders, and Skids) out of cross broken Heat Treated AR400!  It's so strong that it literally stalled his 150 ton press a few times for the sliders.

Front Bumper and Skids:


Check out Luke's "AR" Branding next to the High-Lift Insert Hole:


Sliders:


Winch Fairlead they "whipped" out:


Rear bumper and skids are being finish welded today.  I'll have more pics soon.  These guys are AWESOME at what they do.

[Charles4x4 [OP]]

Small update on the Front Bumper.  Luke, HD and the team went all out - Rock Crushing Approach Angle design:








The Front Bumper, Sliders, and Skid Plates are done and in Powder Coat this morning (they do powder coating in house at 4x4Labs). 

The rear bumper is being finish welded and will go in Powder Coat ASAP - it's the only item we're slightly behind on right now (maybe a 1 day delay). 

They're also working on a cool idea for our exhaust...  They are going All Out for this build!

[redneckcustoms13]

Someone has that mig dialed in and can run it like a robot.