Author Topic: Steel City Racing & Marlin Crawler: KOH 2019 Toyota 4Runner IFS 4600 Build  (Read 4555 times)

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Rockcrawlintoy

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Whatís the plan for the front suspension. I know a 1st gen ifs runner has raced a few times and finished.
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Charles4x4 [OP]

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Whatís the plan for the front suspension. I know a 1st gen ifs runner has raced a few times and finished.

Yes, most 1st gens that have raced in KOH were '85s with SAS, but I think Bailey Cole raced a torsion bar based IFS 1st gen. 

Per 4600 rules, you cannot change the type of suspension, which is why we decided on the 4th gen 4Runner.  V8 Power with IFS Coilovers based front suspension - can't beat the combo.

For the front, I can't go into details yet, but it'll be long travel and extremely strong IFS with 2.5" Coilovers with remote reservoirs in the front.  More to come soon.

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Yes, most 1st gens that have raced in KOH were '85s with SAS, but I think Bailey Cole raced a torsion bar based IFS 1st gen. 

Per 4600 rules, you cannot change the type of suspension, which is why we decided on the 4th gen 4Runner.  V8 Power with IFS Coilovers based front suspension - can't beat the combo.

For the front, I can't go into details yet, but it'll be long travel and extremely strong IFS with 2.5" Coilovers with remote reservoirs in the front.  More to come soon.



Hey BigMike sponser this out and beef that front up with stuff ur prototyping on the 3rd gen tacoma!


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Rockcrawlintoy

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Several people have raced that ifs runner lol last one I remember was Texas Jesus
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This is gonna be fun!!! 
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This is gonna be fun!!!

(Quasi Spoiler Alert)
Wyatt, I can't wait till this 4Runner is in your shop!  :clap:
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Charles4x4 [OP]

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Update: I'm close to being finished with the DD - maybe 2-weeks left - then I can stop driving the 4th gen and the true tear-down begins. More updates below:

In Process:
- Front Suspension and Steering are being fabricated
- Front RCV Front Axle Shafts are being engineered
- Rear RockSolidToys 4-Link Suspension brackets are completed
- Rear Currie RJ60 is being made (not sure if they have done gearing or not yet)
- AEM Fuel System gauges (2) likely go in this week

Still working on:
- URD MAF Calibrator in the mail
- Fiberwerx Fenders in the mail
- PRP Seats being ordered
- Locking down sponsors for Armor and Tires
- Lock down fuel cell dimensions and dual-pump system

I'm also struggling to find reasonably priced 4th gen salvage doors shells (4) and lift gate to gut. If anyone knows of any in the Southeast, PM me!
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Update: I'm close to being finished with the DD - maybe 2-weeks left - then I can stop driving the 4th gen and the true tear-down begins. More updates below:

In Process:
- Front Suspension and Steering are being fabricated
- Front RCV Front Axle Shafts are being engineered
- Rear RockSolidToys 4-Link Suspension brackets are completed
- Rear Currie RJ60 is being made (not sure if they have done gearing or not yet)
- AEM Fuel System gauges (2) likely go in this week

Still working on:
- URD MAF Calibrator in the mail
- Fiberwerx Fenders in the mail
- PRP Seats being ordered
- Locking down sponsors for Armor and Tires
- Lock down fuel cell dimensions and dual-pump system

I'm also struggling to find reasonably priced 4th gen salvage doors shells (4) and lift gate to gut. If anyone knows of any in the Southeast, PM me!

do you have any Keystone/LKQ vendors around? thats what my shop uses for used parts.

damn im hella stoked to see this thing transform
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Charles4x4 [OP]

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do you have any Keystone/LKQ vendors around? thats what my shop uses for used parts.

damn im hella stoked to see this thing transform

Thanks.  Never heard of Keystone before, but there are 2 within an hour or so from me.  Looks like a standard parts store though?

Also looked at LKQ - their pricing is similar to what I've seen before - $500ish a door, which feels really high to me for a shell.  There are some cheaper on Ebay including shipping, which doesn't make sense...

I've already called 10+/- salvage yards.  One had the 4 doors, but wanted $$$.
« Last Edit: Jul 09, 2018, 09:17:06 AM by Charles4x4 »
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Thanks.  Never heard of Keystone before, but there are 2 within an hour or so from me.  Looks like a standard parts store though?

Also looked at LKQ - their pricing is similar to what I've seen before - $500ish a door, which feels really high to me for a shell.  There are some cheaper on Ebay including shipping, which doesn't make sense...

I've already called 10+/- salvage yards.  One had the 4 doors, but wanted $$$.

unfortunately, doors wont be cheap for that. LKQ is the used sales side of that, and Keystone is the new parts side of that. you may get lucky and be able to find brand new door shells for cheaper. im not surprised ebay may be cheaper.  I can look up toyota part numbers for door shells for you to search around?
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Rockcrawlintoy

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What are the door shells for? Why not just gut the doors on there now?
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Charles4x4 [OP]

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What are the door shells for? Why not just gut the doors on there now?

Doors on it now are flawless Limited doors that are worth $$$.  I just need salvage shells (no electrical, glass, motors, etc).  See below.
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Charles4x4 [OP]

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Quick Update: Four salvage doors are being loaded on a pallet as we speak and will be go out tonight.  Picked up all 4 shipped for less than 1 locally.  Patience paid off big and allows me to put $ back into other parts of the budget.

More updates:
- Warn Zeon 10-S Platinum Winch in the mail
- URD MAF Calibrator in the mail
- Fiberwerx Fenders in the mail
- PRP Seats Ordered
- PRP Harnesses Ordered
- Solid progress on the Front Suspension and Steering this week

Will dive into fuel cell and system later this week.  Need to take some measurements of the cargo area before I order a cell - any suggestion on a good type for a good price (size TBD)?

Still looking to lock down my final tire sponsor.  If you've got suggestions, PM me.  I've got good pricing from one option already, but think we can get more.
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Rockcrawlintoy

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As far as tires go you canít go wrong with BFG. They have a big presence in the off road scense and had good support at KOH as well as Nitto. Both have proven tires out there. Also remember donít  air down that low out there you will kill tires
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Charles4x4 [OP]

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As far as tires go you canít go wrong with BFG. They have a big presence in the off road scense and had good support at KOH as well as Nitto. Both have proven tires out there. Also remember donít  air down that low out there you will kill tires

Thanks.  I'm being considered for sponsorship by Cooper (STT Pro), BFG (KM3s), Falken (Wild Peak MT), Nitto (Trail Grapplers), Goodyear (MT/Rs), and Maxxis (Trepadors) for weeks/months, but only one Discounted Pricing sponsorship so far.  This means I've submitted an application for sponsorship or already done some type of direct outreach (calls and emails).

I need to find someone who knows someone at one of these who will jump all-in on this build.  PM me if anyone has any contacts I can use.
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 :biggthumpup:

I have a fever, and the only cure is more pictures!!!!

cant wait to see how this turns out.

Rockcrawlintoy

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Btw Zippo and I have pretty much confirmed going to koh next year and not are down to help in the remote pits
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Charles4x4 [OP]

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Update:
I've been out of town the past week, but here is a quick update on this build:
1) Our new Warn ZEON Platinum 10-S winch arrived yesterday.  It's a thing of beauty and the remote will definitely come in handly for our co-driver at KOH!



2) I knocked out a few small projects, including swapping in a new O2 sensor damaged when we did the Y-Pipe cat delete (this 4.7L V8 is really squeezed in there).  The new sensor eliminted the CEL I was getting.  I'm still waiting on the URD MAF Calibrator to arrive and will install my AEM gauges before we do final tuning.



3) The Salvage doors arrive on Wed.  Then I'll check out the internal bracing and see how much more we want to cut.  I'm hoping they are really light in already gutted condition.

4) We are now only down to one sponsor need for tires.  I've reached out to BFG, Goodyear, Maxxis, Nitto, Cooper, and Falken.  So far Falken and Maxxis have shown strongest interest.

5) I've finalized plans with two additional sponsors.  More to come on these in a few weeks.

Finally, the DD should be back from paint by the end of next week at the latest and ready for reassembly.  As soon as it is done, the interior tear-down on this one will begin along with the doors and front fenders.  Then the transformation will really begin to take shape.  Thanks for your patience!
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Charles4x4 [OP]

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Btw Zippo and I have pretty much confirmed going to koh next year and not are down to help in the remote pits

Great to hear you'll both be at KOH 2019!  I look forward to meeting you there.  I'm hoping you meant "now" instead of "not" above :) - if so, we can definitely use you both in the pits both before and during the race!
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Rockcrawlintoy

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Great to hear you'll both be at KOH 2019!  I look forward to meeting you there.  I'm hoping you meant "now" instead of "not" above :) - if so, we can definitely use you both in the pits both before and during the race!

Yeah I donít know what I was saying. We are down to help
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Update:

3) The Salvage doors arrive on Wed.  Then I'll check out the internal bracing and see how much more we want to cut.  I'm hoping they are really light in already gutted condition.


Generally they come fully dressed when coming from salvage companies
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Charles4x4 [OP]

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Generally they come fully dressed when coming from salvage companies

I only bought the Door Shells and Exterior Handles.  No glass, motors, electrical, etc.  We'll see if it even comes with any door hardware like hinges/latches/lock bars.
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Charles4x4 [OP]

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I thought it may help to give a glimpse into the behind the scenes a little more.  If you're only watching this thread for the hardcore stuff that is yet to come, skip this post.

From what I know so far, here is what it takes to make something like this Steel City Racing KOH project happen!  Since I really committed to this build in May, I've spent a lot of time:
- Reading the Ultra4 rulebook 3-4 times and making lists of everything I have to get done to pass tech and stay within the 4600 class rules
- Creating a budget and a "dream build" list of To-Dos that fit the vision of this build and the 4600 class rules
- Pulling together the story of this project, which was critical for grabbing initial sponsor interest
- Filling out sponsorship paperwork, online forms, and legal documents - probably 50 forms filled out in total
- Building momentum with sponsors.  Once you land 2-3, it does get easier.
- Landing sponsors, we are now up to 15 with 1 mandatory (Tires) sponsor remaining and 3 optional ones outstanding
- Creating relationships with groups like Marlin Crawler and RockSolidToys who believe in your vision and are willing to do whatever it takes to make it happen.  Without BigMike and Wyatt in particular - and their willingness to connect us with others in the industry and build amazing parts for this rig - this build would be tough!

In today's age, the currency is no longer build-threads on forums.  I'm doing build threads like this for ideas, diversity of thought, and because I think they are mostly extinct today which is a shame.  Instead, it's social media that brings sponsors to the table.  So, I had to:
- Create a rendering of how the vehicle will look
- Create social media campaigns for Facebook and Instagram (more time consuming than I had expected)
- Get the word out on forums, family & friends, and with Toyota enthusiasts.
- Constantly post new content to keep the interest (tough some days)

I then was finally able to get rolling - so, I started
- Looking for a no-rust, low mileage, affordably priced 4th gen v8 4x4 Sport or Limited (much harder to find than expected)
- Finishing my DD so I can tear into this one (still have a few weeks left - it's in Paint now)

We entered Phase I - Engine Performance, which I could do while the DD wasn't complete:
- Install Magnaflow exhaust, URD y-pipe with cat delete, new Denso O2 sensors, aFe Power air intake, URD 170 degree thermostat, AEM AFR and Fuel Pressure gauges, Doug Torley Headers (not yet installed), and URD MAF Calibrator (in the mail)

At the same time, I am still acquiring parts:
- The Warn ZEON 10-S Platinum winch arrived
- Fiberwerx Fenders are in the mail
- Front seats and harnesses are in the mail (seat brackets arrived)
- Salvage doors arrive on a 18-wheeler today (still looking for a liftgate)

Once the DD is done in a few weeks, I can tear out the 4th gen interior and remove exterior stuff, remove the stock doors, start on the fuel system, and work on armor (more to come here with a sponsor I just landed on Monday).

As we speak, the following is also in process:
- Rear RJ60 is ordered and being built
- Front suspension prototype should be complete in the next 2-4 weeks
- Front steering prototype is on the same timeline
- Front RCV Next Gen axle shafts are being engineered but won't be ready till the Fall
- Rear bumper prototype is being engineered and will be ready in the Fall
- Atlas II is being ordered
- Rear 4-Link is done and ready to be installed once the front suspension is on
- Coilovers, Coils, and Shocks are ready to go once the suspension is on
- Tires (still need a sponsor here) and Wheels will be ordered
- Driveshafts are envisioned and final specs will be dialed in once the suspension is on and final angles/measurements can be taken
- Roll cage is envisioned

All of that while balancing family life and running a small business.  Note that the 4runner will be in CA for the real fabrication, starting in August.

So, if you're just looking at pictures, I think you may not be seeing the full story of what all has gone into this build thus far.

Lastly, as a shameless plug, if you want to help this build to keep up momentum with happy sponsors, please follow it on IG and FB and tell your friends.  We need more followers - which will come from word of mouth from forum members like you and with momentum once the "sexy" fabrication side of the build really takes off.  Social media is today's sponsorship currency, period!

And please PM me with any ideas or contacts you may have for Tire Sponsorship!
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Charles4x4 [OP]

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More parts arrived today! These Fiberwerx front Fiberglass 4.5Ē Bulge fenders will really help us for the 35s while keeping COG low. I plan on installing them when the salvage doors are ready (should be here next Wed).





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Trailer Build http://board.marlincrawler.com/index.php?topic=103261

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Charles4x4 [OP]

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Took measurements of the cargo area stripped down for the fuel cell and spare tire last night.  I'm thinking fuel cell on the platform just behind the rear seats today (removed for KOH) and spare standing straight up or slanted 45 deg toward the front over the rear portion of the cell. 

The fuel cell area behind the seats is 42 W x 26 D.

The spare tire area behind the cell before the liftgate is 58 W x 14 D

Max vertical height 39" in center, min right at Liftgate 35.5" - will likely gain another 1" with full teardown.





We'll be using Alltech baffles - no foam.  Researching fuel cells later today.
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Charles4x4 [OP]

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Haven't had a ton of time to search, but there seem to be really cheap and really expensive fuel cells.  Jaz Pro Sport II seems to be right in the middle with good reviews.

Wide & Short 22 Gal (34-1/2"L, 18-3/4"W, 10-1/2"H):
https://www.jegs.com/i/JAZ/547/280-122-NF/10002/-1?CAWELAID=230006180039258847&CAGPSPN=pla&CAAGID=15769068431&CATCI=pla-176566670711&CATARGETID=230006180003464013&cadevice=c&jegspromo=thirdparty&gclid=CjwKCAjwkMbaBRBAEiwAlH5v_k_wp5S7MAXA6VQ0fzAfrTvRfKEjKK9AdZMxG7T7j__Q1av8h8U5IhoCCYYQAvD_BwE

Wide & Short 32 Gal (34"L, 17-3/8"W, 14-3/8"H):
https://www.jegs.com/i/JAZ/547/280-032-NF/10002/-1?CAWELAID=230006180039258838&CAGPSPN=pla&CAAGID=15769068431&CATCI=pla-176566670711&CATARGETID=230006180003464013&cadevice=c&jegspromo=thirdparty&gclid=CjwKCAjwkMbaBRBAEiwAlH5v_ljV4lCCleaqRixsVttHA5X6XgXeoE5-Fh1pbkEwfyXGFvuseCjG0RoCJiUQAvD_BwE

I can fit either and Artec makes a nice mount for both.

I can see the need for a 32 Gal cell with a blown LS that gets 3-4 MPG.  But we're using a slightly modified 4.7L Toyota V8.

- Is the extra capacity of the 32 Gal needed and worth the extra weight?
- Is there high probability that I'm going to need more than 22 Gal between pits at KOH or other Ultra4 races, Mint 400, or even Baja if that dream ever comes true?
« Last Edit: Jul 20, 2018, 11:04:08 AM by Charles4x4 »
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Charles4x4 [OP]

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Stock 2016 V8 MPG is 17/20.  Cut that in half for race conditions and power modifications we've done.  Maybe 8-10 MPG.  5 MPG worst case scenario.

- 10 MPG and 22 Gal = 220 Miles
- 5 MPG and 22 Gal = 110 Miles

- 10 MPG and 32 Gal = 320 Miles
- 5 MPG and 32 Gal = 160 Miles

2018 KOH Total Distance:
4400 = 202 Miles
4500 / 4800 = 136 Miles
4600 = 124 Miles (us)

Given the Main and Remote Pits - Even at 5 MPG I don't see how I need more than a 22 Gal cell right?

If I ever get to race it at Baja, that's a great excuse to upgrade to 32 Gal.
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Toyotadon

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This looks like a lot of fun, and I love the challenge.  I've watched the KOH live stream for several years now, and if I can ever make it out, would be up for helping a team like yours in the pits.

Rockcrawlintoy

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Stock 2016 V8 MPG is 17/20.  Cut that in half for race conditions and power modifications we've done.  Maybe 8-10 MPG.  5 MPG worst case scenario.

- 10 MPG and 22 Gal = 220 Miles
- 5 MPG and 22 Gal = 110 Miles

- 10 MPG and 32 Gal = 320 Miles
- 5 MPG and 32 Gal = 160 Miles

2018 KOH Total Distance:
4400 = 202 Miles
4500 / 4800 = 136 Miles
4600 = 124 Miles (us)

Given the Main and Remote Pits - Even at 5 MPG I don't see how I need more than a 22 Gal cell right?

If I ever get to race it at Baja, that's a great excuse to upgrade to 32 Gal.

Don't forget crawling will use a ton of fuel. I would think a 22 would be more than enough and just keep some fuel cans ready in the pits. Are they requiring dry break fuel connections?
« Last Edit: Jul 20, 2018, 04:35:34 PM by Rockcrawlintoy »
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