Topic: How To: Bob an Early Model 4Runner Top

[CTENG in KS]

Decided to shorten up the top and gain a mini bed in the back...so here we go.  The idea was to keep the sliding windows for the back seat intact.  Got everything cleaned out and taped up...ready for the cutting!

[CTENG in KS [OP]]

Start it out by drilling a hole at the framerail and we're off with the new jigsaw!

[*** YELLER ***]

them shure is purdy tools 

that should look sick when yur done 

I'll be watching 


 

[CTENG in KS [OP]]

Yup...that's def. cut!

[CTENG in KS [OP]]

Need to translate the angle from the first cut to the second, but I decided to make the second along the rear windo line, then translate the angle later to make the first cuts easier.

-Yup...makin a mess! 

[CTENG in KS [OP]]

Kool thing...the headliner has so much glue that it trimed right along with the shell so I will be keeping it...more to come on that later.

Then I used the sawzall to get through the bottom flange at each end of the cuts.

[CTENG in KS [OP]]

Then she started coming apart piece by piece! 

[CTENG in KS [OP]]

I have cut approx 31.5 inches out of the top and once I get the rear piece trimmed to math the angle on the front we will join em back up.  Here is where I left her for the night.
 

[DTB]

If your neighbors didnt think u were crazy before, they definitely will now!

[CTENG in KS [OP]]

them shure is purdy tools 

that should look sick when yur done 

I'll be watching 


 

All Hitachi!  Good prices and the tools are killer.

[CTENG in KS [OP]]

If your neighbors didnt think u were crazy before, they definitely will now!

Yeah...they look at me funny.

[BLACKDOG]

Yeah...they look at me funny.

I bet they do.  What're you going to do about the rear window/wall between the bed and the cab?  gonna do a removable midgate thing, or a solid wall with a plexi window? 

mabye you could still use the original tailgate (trimmed down) with glass in the bed, retain the window motor and stuff, and then use a truck tailgate for the bed  

  looks good bro, can't wait to see what you do with it

[Rainer]

That is awsome, i have the same idea going through my head, i want a mini bed. So when i lift it I may be doing the same thing, but i will have a second top to do it on just in case i screw it up.

Mark

[CTENG in KS [OP]]

I don't have anywhere to put a second top.  I have not decided what route to take for the back panel.  I have been considering using the original glass and building a bottom panel.  I am not interested in it rolling down, I am happier to pull all the weight of that stock gate and motor off the truck.  With respect to weight I could save some by going plexi of lexan, but the glass may prove more easier.

[Rainer]

I want to put the tail gate with the topper,so i can still roll down the window and it still has a sealed cab, it would take alot of fab work, then i would put a tire carrier in the mini bed or something. I havt decided, im tossing a couple of ideas around. It looks good though.

[*** YELLER ***]

schweeeet  how ya gonna put them back together  you good at fiber glassin'



 

[BLACKDOG]

schweeeet  how ya gonna put them back together  you good at fiber glassin'



 

I'm betting we're gonna find out.

[CTENG in KS [OP]]

I have work and school experience with composites...

I have seen a bunch of these bobs crack off road cause they don't glass it properly so this thread will have a few lessons on proper technique.  I guarantee no cracking if done properly.

[weirdtimes_7]

Are you going to keep that back peice you cut off?? Can you make some kind of system so the smaller peice can snap into place if you ever want it to??? Just trying to see if there are any other way's to keep your old cab...

Looks good by the way, and looking forward to seeing your progress...

military_stang
:repsect:

[CTENG in KS [OP]]

The middle piece with the back windows is going.  The rear piece where the tailgate window was will be grafted onto the remaining front part. 

[Wermz84]

Looks good so far!         Cant wait to see the finished product...

I have work and school experience with composites...

I have seen a bunch of these bobs crack off road cause they don't glass it properly so this thread will have a few lessons on proper technique.  I guarantee no cracking if done properly.

Were going to hold you to it.         


Let me ask you a question about Fiberglass without doubting your work:   

I was under the impression that all glass body work will eventually crack due to the fact that steel and glass flex differently, am i mistaken then?

[ty4runner]

must have more pics!

that looks good, I'm doing sort of the same thing with my 2nd gen 4runner, I making a rag top for it

[toyo487]

I like the look a lot, I have cut a 4runner top similar the the way you did it but mine didn't come out looking as good.  They are much more difficult to cut than I had expected.   Cant wait to see the final product.  I may have to find a second top and try it my self.

[CTENG in KS [OP]]

Follow me, I'll show you the way!

[Wermz84]

lots of   please!!

[CTENG in KS [OP]]

What..the plethora of step by step pictures so far isn't doin it for you?

Don't worry, there will be full documentation!

[Wermz84]

What..the plethora of step by step pictures so far isn't doin it for you?

Don't worry, there will be full documentation!

haha..  they are great so far.   I am eager to see how to do glass.   

[CTENG in KS [OP]]

Time to break for lunch but I figured I would give all you web wheelers the update before hand.
I got the angle cut on the back piece to pretty well match the front.  After that I got with the grinder and tapered the edge of each side to create a V-notch at the joint.  Don't make it a deep pansy notch...you want the V to be fairly wide and feathered out.

[CTENG in KS [OP]]

Lining it up was a pain.  I used some clamps to keep it from slipping backwards then cardboard shims to get it sitting at the proper angle.
This is also the right time to put all the power tools away and get your clean on.  There was dust everywhere so I spent about 20 min witht he shop vac.

[CTENG in KS [OP]]

Now lets take a couple minutes and talk fiberglass.
Like all composites, fiberglass is the combination of two or more substances with differing properties to form a single structure.  In the case you have the strands of glass suspended in a matrix of resin (usually polyester or epoxy).
You will find fiberglass in several different configurations.  There is loose strand which is essentially just what it sounds like.  There is fiberglass mat which is like the pressboard of fiberglass.  It is loose strands tangled together in every which way into a cloth mat.  This is good for body panels and such, not great for structural stuff.  Finally there is fiberglass cloth (woven).  There are many different type of weaves, however, unless you are going to a specialty place, you will commonly only find std. cloth weave.  This is a 1 to 1 over under weave which is what they sell at you local autoparts store shown here: