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

[Charles4x4]

Update:
Over the past 2-days, Otwell has been knocking out our Frame Mounts (this took a TON of effort), side protection bars, and vertical windshield bracing.  I'll let the pics speak for themselves:

Current Helmet Headroom on 5'11" Person is 4-5":


Frame Mounts using Grade 8 1/2" x 2" Hardware (All 3 on Passenger Side shown):






Interior Sandwich Plates to Frame Mounts:




Side Protection Bars (set at top of Seat Cushion height):


Random B-Pillar Floor Brace to show where seats will likely end up.  Note Otwell is making the mounts to tilt the seats back 10deg back for comfort and visibility reasons:


I was able to borrow a GoPro Hero 4 Black from a friend and picked up (2) 128 GB MicroCards so we can hopefully record the full race.  This will be mounted using a GoPro 1.5" to 2.5" Roll Cage mount - likely on the Dash Bar:


Finally, I finished sync'ing our Dual XGPS160 to the iPad Pro, downloaded LeadNav Software, and purchased the LeadNav Pro Pack Annual subscription.  For navigation, I really can't do anything else till the Course Maps are released on Friday 2/1 at 8pm PT from PCI Race Radios.  We plan to start pre-running on Saturday 2/2.

[Rockcrawlintoy]

Looks good. Are you sellin shirts? i would buy one to support the team. Any
 pics of front and rear suspension yet?

[Charles4x4 [OP]]

Looks good. Are you sellin shirts? i would buy one to support the team. Any
 pics of front and rear suspension yet?

Wish we had time to sell shirts.  We only got enough for the team.  Maybe at a later date!

More pics coming soon.  RST is on site the next 3-days on Atlas II and Rear Suspension.

[Charles4x4 [OP]]

Our team is excited to announce another sponsor: Pro Eagle Jacks.  We'll be running their 2 Ton "The Beast" Big Wheel Jack and Bed Mount on the car at KOH.

The Beast:


Bed/Floor Mount:


After speaking with Hobie about this a few weeks back, we both felt a Pro Eagle was the right choice for KOH.  It does weight a bit more, but is much safer, faster, and more compact than alternative Scissor, Bottle, or Hi-Lift Jack options. 

Let's hope we don't have to use it during the race!

My Co-Driver for EMC, Matt Tatum is a Professional Firefighter and Paramedic.  He handled our First Aid Kit - the bag is from Rago Fabrication:

[Charles4x4 [OP]]

Shot Update on Yesterday's Progress:
The A-Team as there yesterday working on the 4Runner.  Matt with RockSolidToys, Wyatt with RockSolidToys, BigMike with Marlin Crawler, and Robert with Otwell Welding and Fabrication.


Robert Otwell doing what he does best:


Artec Jaz Pro Sport Fuel Cell Mount being integrated:


Fuel Cell Test Fitting:


I'll be working on the final fuel cell hook-up next week along with some Aeromotive Phantom enhancements.  Per a call with JT this morning, I need to add a ball valve on the Supply line.  I ordered one that will be there on Mon.

[Charles4x4 [OP]]

Update:

Starting Monday, I will have less and less time to update this build thread since I'll finally be on site in CA helping the team.  I know not all of you like Facebook or Instagram, but it much simply more efficient for me to post quick pictures there while we are in the final stretch crunch of the build.  So, if you can, follow us on FB/IG to stay up to date. 

Also, these build threads will likely lag from now until race day, so don't panic if you don't see regular updates.  We'll be working hard and will be on the start line on Wed Feb 6th!

Update on Otwell's Work:

Here's where we decided the spare will go for KOH:


Note that we test fit a ton of potential locations in both the Cargo and Passenger area, but ultimately decided this is the best spot for weight, COG, and visibility reasons.

Fuel Firewall per Ultra4 Rules is Done except for metallic tape we'll apply to perimeter:


And here is the Top Half of the B-Pillar Triangulation.  I spoke with Otwell tonight and we decided to get rid of the middle vertical brace - it was overkill, weight, and hurt visibility/accessibility.  So it'll just be an X when the Bottom Half is done:

[Charles4x4 [OP]]

Continued from above...

Update on RockSolidToys Work:
The team has been crushing it the past few weeks.  Matt and Wyatt put in 2-days last week and 3-days this week.  Wyatt brought the Full RST Team out today to stay on schedule.

Per the posts above, last week they stripped the rear end and pull the Toyota T-Case.  Then they started working on the Atlas II.

Atlas II Shifter positioning:


If you look closely through the cage bars, you can see the Shifter Base they fabricated:


Today the Dynatrac ProRock 60 finally got some attention - it's a beast!


Here is a "KOH Proof" reinforced version of RockSolidToys Rear 4-Link brackets:


Upper and Lower Frame Mounts are Done:


Dynatrac ProRock 60 is Slid into Place and you can also see the Atlas II in position in this pic:


Lower Axle Mounts are Done:




Action shot of RockSolidToys and Otwell doing what they do best:


We also got to check out the Icon 2.5" Rear Shocks (12" Travel) with RR and CDCV (on the fly tuning).  They are impressive!


The team is taking off tomorrow, but we'll be hitting it hard on Monday and RST is back at Otwell's on Wednesday.

[Rockcrawlintoy]

Full float pro rock?

[Lewis Hein]

Great work! I think I spy my favorite welder of all time hard at work in one of the Otwell shots too.

[Charles4x4 [OP]]

Quick No-Pictures Update:
- Otwell finished the cage on Mon. Pics on FB/IG
- After my flight got in and I drove over from LAX, Otwell and I spent all of Monday night inventorying all the parts and To-Do's left on the car.

- Today I finished gutting the final components of the 4Runner (Doors, Glass, Random wiring, etc).

- Otwell got the Passenger Seat completely done - it's in position, mounted to the frame, harnesses done, etc.

- Otwell is 50% done filling in the sunroof and finished a quick Air Pumper mount.

- I finished also making all Aeromotive upgrades to our fuel cell including their new Apex siphon system to ensure no fuel starvation during the race.

- I also got the PowerTank filled and picked up all the random parts we will need from the hardware store (hose clamps, grade 8 hardware, light blue paint for number plates) etc.)

Tomorrow RockSolidToys and Otwell are both in the shop working on final fabrication and I'm working on more random stuff.

I admit that I was exhausted from the trip and time zone change today and simply forgot to take a bunch of pictures today.  I'll try to do better tomorrow. 

I wake up early to pick up all our spare Tires/Wheels - they have been at one of Marlin and BigMike's friends houses for a few months now.

[Charles4x4 [OP]]

I have to get to the shop, but wanted to post a few recent pics for anyone who isn't on FB/IG:

Cage is done - Otwell is awesome!  Lots of Triangulation:


Aeromotive Phantom Jet Siphon to add second fuel pick-up at opposite side of tank:


Sunroof Patch:


RockSolidToys Crossmember Mods:


Mounting these KMC XD222 Enduro Beadlocks is painful.  The bolts move on you as you tighten.  Taking me way too long to get these mounted.  I'm only working on them at night after everyone else is gone:


3 Extinguishers mounted on Drake Quick Release mounts:


PRP Seats, PRP Harnesses, Rugged Radios M3 Pumper are in:






More to come.

[4runner17]

So I gotta know, what’s the secret to your wife letting you spend money like this? Lol if I only knew my rig would be built already lol

[Charles4x4 [OP]]

The team crushed it today.  We got ahead of our To-Do list and for once we all got to leave the shop early around dinner time to get some rest before tomorrow's final push.

Updates:
Otwell Built spare tire mount:


Otwell Built ARB HD Air Compressor Mount in engine compartment for Air Lockers (and backup onboard air to PowerTank if ever needed):


Otwell Built T-Bar Handle + Navigation Mount with Quick Release.  The T-Bar locks/unlocks and rotates up and down:
- Down for the co-driver to hold onto while racing
- Up past the windshield when we need to get out.


Currie AntiRock Rear Sway Bar goes on tomorrow:


Otwell Built Pro Eagle Big Wheel Jack Mount with Quick Release:


SFI Compliant (almost as hard as the roll bar itself) Roll Bar Padding installed above all Helmet areas:


RockSolidToys Rear 4-Link is tacked in (will be finish welded tomorrow):






Atlas II is done except we just need to connect shifter cables to shifter assembly built by RockSolidToys.

Tomorrow we have 4 teams working simultaneously as the Final Big Push to finish everything except Exhaust, Driveshafts (done, but not in hand yet), and Testing.  If we don't finish, @rustynailjustin and our shared pit crew will come help knock out anything left on Sun.

The car is only a few minutes from the Lakebed now.  We hope to be testing in "similar terrain" early next week.  Then the wrap late next week and race prep begins next weekend.

[Charles4x4 [OP]]

So I gotta know, what’s the secret to your wife letting you spend money like this? Lol if I only knew my rig would be built already lol

  I am blessed!  I have an amazing wife and family whom I miss dearly while I'm in CA working on the car (my wife will be here Tues-Sat of race week though).  We have an amazing team who is literally attacking this build and getting it done.  We have amazing of sponsors who have helped sponsor a ton of amazing products used on this build.  Finally, I pray a lot - for my family, our team, our sponsors, and this adventure overall - and then I trust that amazing things are going to happen.

Without any one of these, this build would be Dead.

[4runner17]

Thats awesome, to be able to live your dream. In a way we all here I bet kinda feel like we’re living it through you. Not everyone gets the opportunity. Congratulations and the best of luck!

[Charles4x4 [OP]]

We've been at the shop 12-15 hours a day, so I'm going to make this post brief:

8 Tires/Wheels are done (7 pictured + 1 in car):


Fuel system is back in and done:


PowerTank is installed:


Wiring Fun:


Atlas II shifters and RockSolidToys made shifter box done:


Got 10-mins of work left on the Atlas II (fluids and a few connections):


Justin Reece and Team came out to help today - it was a HUGE boost to the build.  A few other team members ended up with a conflict, so having Justin, Bird, Andrew, and Josh there was a massive help along with Robert Otwell:




Interior is Done:


Front Suspension is Done (huge thanks to Justin and Team here), but I'm still waiting for the release to be approved so no pics just yet.

Tomorrow we have to finish the rear suspension and install the driveshafts.  We decided to cut the truss down and drop the upper links down to pick up a few more inches of up travel. 

We also have to get the car to an exhaust shop tomorrow.  We hope to have time to do some testing tomorrow, Friday, and this coming weekend.  It gets wrapped this Wed/Thurs.

[Charles4x4 [OP]]

Update:
First of all, without Wyatt Scott and Matt with RockSolidToys, Robert Otwell with Otwell Welding and Fabrication, and Justin Reece (@rustynailjustin), Bird, Andrew, and Josh - this car would not be done in time for the race.  HUGE THANKS to each of them!

As of 1am last night, the car is in San Bernardino at Syndicate Offroad getting the wrap installed, so today is a much needed and well deserved rest and recovery day for the rest of the team.  Special thanks to Sergio for meeting me at midnight last night to make the hand-off without losing any build time!

We've pushed hard from before sunrise to late at night each day over the past few weeks.  The car is amazing.  Each component crafted and installed by a team who loves this build and puts their all into everything we touch.  We were handed a Phase III timeline that was close to impossible to meet and we're going to make it.

Timeline:
     Today/Tomorrow - Wrap
     Fri Morning - Exhaust
     Fri Noon till Late - Finish Anything that is Left
     Sat: Shakedown Run in Lucerne Valley near Otwell's shop so we can check everything afterward and make modifications as needed
     Sun: Shock Tuning session with Icon
     Mon: Tech at 8am

Current State: Everything is done except:
- Drivers Rear Shock Hoop finish welding
- Drivers Rear Remote Reservoir Mount
- Passengers Rear Shock Hoop finish welding
- Passenger Rear Remote Reserevoir Mount
- Passenger Rear Air Bump
- Install Rear Limit Straps
- Finish mounting Rear Brake Lines (temp mounted now)
- Install revised Driveshafts (F/R)
- Remount 2/3 Skid Plates after Exhaust is done
- Add small Skid for Rear Winch Solenoid
- Perform Driveway Alignment and Set Suspension to Softest Setting
- Install Fluids Container Tool Box in Cargo Area (90% done)
- Preload Winch Lines

As with any big push, we did have some issues, notably:
- The Atlas II and our Drivelines Inc driveshaft ends didn't mate, so the driveshafts are being re-done as we speak and will be ready tomorrow.

- The new Solenoids on the ARB HD Air Compressor for lockers didn't have the plugs we needed (instructions said to "discard" them, so we did) so we had to improvise with some random bolts until we get the correct ARB fitting plugs tomorrow.

- The ARB HD Air Compressor electrical connector was faulty and caused fuses to blow in our comms.  Once we fixed the comms and found issue, we cut out the plug and hard wired it all in.  This is done.

- Our rear Dynatrac ProRock 60 axle truss was too high, causing our upper links to hit the factory crossmember and limit travel.  We cut off the top of the truss (1/2" plate), cut the truss down, and remounted our upper links.
 This gained ~4" more uptravel in the rear.  This is done.

- Our front suspension spindle was hitting the coilovers at max down travel, so we had to raise our limit straps slightly and then set our air bumps.  While doing so, we had our Passenber Huge D60 equivalent RCV slip out and it took Justin, Robert, and I a while to pull the huge Icon coilovers back off to get the RCV to set back into place without any issues.

- Our Atlas II Rear shifter wouldn't come out of Neutral.  A couple calls to Steve at Advance Adapters and the issue was resolved.

- Our transmission shifter contacted the Atlas II shifters so we had to heat/bend it to vertical.

- Added a Fuel Line Shutoff valve to our Aeromotive Phantom system (pretty tightly sealed as it is) per Ultra4 tech request.

- We had to overnight different lug nuts for the rear, a replacement rear view mirror after we broke the first one, another fuel filler neck to adapt to our setup, tons of Grade 8 hardware, an extra PRP push rod for the safety nets, etc.

Overall, the team has been killing it.  I couldn't be more proud of what we have accomplished.  Here are some pics from yesterday:

Drivelines Inc. Driveshafts:


Sitting on All 4's:


LeadNav setup and Charging (requires special 3.1amp charger wired to battery to keep up with software on iPad Pro 10.5):


Got the tiny, well protected Front View Rock Camera wired and mounted (drilling through AR400 is tough):




Otwell Mounted PRP Safety Nets with Upper and Lower quick release rods:

[Charles4x4 [OP]]

3rd Row Glass Removed and Sheet metal Fitted on Passenger Side:


Fuel Filler for 3rd Row Sheet metal on Drivers Side:


Interior 100% Done:


Video of Otwell and Justin Reece Transmission Shifter Bending:
https://scontent-sjc3-1.xx.fbcdn.net/v/t1.0-9/50720466_497993324057946_4366614162315411456_n.jpg?_nc_cat=107&_nc_oc=AQlL6myV_XHC2BkUhQXp92lenMcO1o2lYHo1c1SmWqlH3IduyjKeazeubd3Ea5L-LkE&_nc_ht=scontent-sjc3-1.xx&oh=b6997b72f30886035b6e1a86c519d00d&oe=5CBA69E3

Back on All 4's again:

[Charles4x4 [OP]]

Wyatt, Robert, and Matt helping me get it on the trailer at 10pm last night with no driveshafts - thank goodness for Front & Rear Warn Winches (clothesline effect) and Brakes:








I arrived at Syndicate Offroad just after midnight to meet Sergio.  They have a solid plan and sequencing to knock out a 1-week complex wrap in 2-days.








I'll pick it up Thursday night and have it at the Exhaust place in Apple Valley at 7am on Friday.  Wyatt, Matt, and Robert will then pick it up before lunch and knock out our final to-do's while I pick up my co-driver at LAX and handle the rental jeep and RV stuff. 

We then meet @rustynailjustin on the lakebed on Sat after our shake down testing is complete and everything has been checked over and over.

Suspension Tuning on Sun.  Tech on Mon.  Pre-Running Sat-Tues.  Race on Wed.  More to come...

[:)bestgen4runner]

How was towing the 4Runner on the trailer backwards?
I have done that before with a diesel superduty on the trailer it was super scetchy.
Trailer move around much with the weight at the rear?

[Charles4x4 [OP]]

How was towing the 4Runner on the trailer backwards?
I have done that before with a diesel superduty on the trailer it was super scetchy.
Trailer move around much with the weight at the rear?

Not too bad but not ideal going down the mountains between Hesperia and San Bernardino. We had no choice. Thank goodness for Warn and Bubba Rope - we were using both Front and Rear winches at once to get it on and off the trailer.

[:)bestgen4runner]

Not too bad but not ideal going down the mountains between Hesperia and San Bernardino. We had no choice. Thank goodness for Warn and Bubba Rope - we were using both Front and Rear winches at once to get it on and off the trailer.

I'm glad you made it safely. I will never do it again unless it's an absolute last resort.

[4runner17]

So what’s the plan for after the race? Keep it and wheel it or just pure koh rig?

[Charles4x4 [OP]]

So what’s the plan for after the race? Keep it and wheel it or just pure koh rig?

I’d love to do more of the epic races - Baja 1000, Mint 400, etc if we get the chance. Until then, it’ll be a family wheeler till KOH 2020 when we go again!  I’m not big on the short course races.

[bigarms23]

Robert sent me pics of the wrap and it came out amazing

[Charles4x4 [OP]]

This is probably my final build stage post.  The wrap and exhaust are done.  Tomorrow while I'm picking up my co-driver, RV, and rental Jeep for KOH in LA, Robert Otwell and RockSolidToys will be wrapping up the final 4-5 hour To-Do list.  We hope to begin Testing late tomorrow or early Sat depending on daylight.

Since my last post, the 4Runner has been wrapped and exhaust is done.  Note that we have a few walk-around videos on IG/FB if you want to check them out.

Syndicate Offroad did an amazing job on the wrap.  It was a 1-week job and I asked them to get it done in 2-days.  To my surprise, they put 5 guys on it for ~18 hours straight to buy us more time for build completion and testing.
 Because of their commitment to this project, we got to install the exhaust a day early and pick up a half-day on Friday for Build Finalization and Testing.

Enough talk, the pictures speak for themselves:







Walk-Around Video:
https://www.facebook.com/SteelCityRacing4x4/videos/1196420633857265/

It rained on the way back...not fun fighting a tarp on the side of I-15 in a downpour...  All part of the experience I guess.


Exhaust being installed.  We had to re-do from the Y-Pipe all the way back to ensure everything is tucked in tight.


On the lift.  Note the rear suspension is cinched tight with big Tie Downs from the ProRock 60 to the frame so the coils wouldn't fall out due to Limit Straps not being installed yet.




High and Tight:


Headed back to the Shop for the night!


While I know the wrap isn't functional, the feedback we've received has been outstanding.  Our sponsors are happy, our followers love it, and we're getting a lot of media attention.  So much that we actually got named one of the Top 5 Most Innovative Rigs at KOH 2019!

I'm proud of what the team has accomplished and I think the wrap was the ideal way to put the finishing touch on an amazing build phase.

Now, after tomorrow, we turn our focus 100% to Testing, Prepping, Prerunning, and EMC next Wed!  We'll be in the desert from here on.  If you want to see what we are up to, follow us on FB/IG. 

The next time you hear from me, it'll likely be a Post Race recap.

[Charles4x4 [OP]]

One last post.  Because our driveshafts aren't in yet, we had to use our Front and Rear Warn winches, Bubba Rope Gator Jaw Pro Shackles, and Odyssey Battery to get the truck On and Off the RockSolidToys trailer.  We did it 6 or 8 times in total - it was comical.

Brief video posted here while at Syndicate Offroad.  I think they posted a better one.
https://www.facebook.com/SteelCityRacing4x4/videos/2218187011832420/

Thank goodness for our Odysset 12 amp Battery charger.  It kept our Odyssey Extreme Series Battery going strong for weeks and a lot of heavy winching.


That's it for the night.  Another bright and early start tomorrow!

[Charles4x4 [OP]]

Hey everyone.  We are home safe and sound!  Thanks for following us over the past few weeks here and on social media!  Matt (my co-driver) and I made it home last night at 2:30am after a 32-hr push (27-hrs drive-time) through the last two days/nights.  To say I feel a little tired right now would be an understatement.

Once I get everything unloaded and caught up on work stuff, I'll post a proper update from the week before the race through last night. 

Overall, it was a wonderful experience.  We wouldn't have changed a thing and we learned a ton.  Best of all, we are now extremely well prepared with true experience, an amazing and innovative car that is 95% ready to go, a sound game plan of upgrades and logistics for 2020, and an amazing wife and family who still support our dream of finishing KOH!

More to come over the next couple of days.

[zippo]

Watching this and having gone to koh a few times. I really want to build a 4500 class rig. Might hit you up for advice!

[Charles4x4 [OP]]

Final Build Recap from ~2-weeks ago:
I believe my last post left off on Thursday before the race leaving the Exhaust shop.  On Friday, while I went to pick up my Co-Driver from LAX and the RV from Cruse America, the team was hard at work on Front Suspension, Rear Suspension, and the toolbox:

Marlin Crawler New RCLT (Rock Crawler Long Travel) and Otwell Fabrication:


RockSolidToys and Otwell Fabrication:


Toolbox:


The team worked till around midnight on Friday so we could start testing on Saturday in Cougar Butes:
https://www.facebook.com/SteelCityRacing4x4/videos/2056943234425771/

https://www.facebook.com/SteelCityRacing4x4/videos/2317278428503816/

https://www.facebook.com/SteelCityRacing4x4/videos/1398237503652654/

https://www.facebook.com/SteelCityRacing4x4/videos/1398237503652654/

https://www.facebook.com/SteelCityRacing4x4/videos/1398237503652654/

https://www.facebook.com/SteelCityRacing4x4/videos/1398237503652654/



First Shakedown Testing showed a few flaws, but everything performed extremely well - better than expected:


After a thorough check, we noticed that we needed to replace a couple Wheel Studs, so we replaced all 12 on the front just in case.  We also had a C-Clip on the Front Passenger side lower A-Arm to Spindle that needed modification, so Otwell knocked that out for us:


We then loaded up the truck for a Suspension Tuning session with Dylan at Icon.  Our Rear shocks got tweaked, but our fronts were setup for Dual Shocks (which we cannot run in 4600) so they got a major overhaul:


We also had to drop our Rear Shock Mounts at the axle by 1" on each side to gain a bit more travel before our rear Air Bumps maxed out:


After this, we headed to the Lakebed for good:




Race Week Recap coming next.