Project Never Easy

[4RunnerChevy]

Very Nice 

[hansi530]

do i see 3 tcases there

[Peterbuilt84]

do i see 3 tcases there

No, just stock duals. Triples would be crazy though lol

[4RunnerChevy]

Well, whats the deal buddy, you got it rolling yet.  Hope you get some wheeling in before school.     If not I can get a bunch of drunks together and test your truck while your away

[Peterbuilt84]

Haha. No real updates unfortunately. Duals are in and my rear driveline is ordered. Just have to wait for it to get back.

I've been working on the rust, hope to get it finished up tomorrow. I have to figure out what I'm going to do for a crossmember. The idea I've been kicking around in my head is to copy the 4xinnovations mount out of pipe. Then I have to build my front driveline and do my front bumpstops.

If I really bust ass I might get it done by labor day weekend. Seems like the list is never ending.

[csb]

Just go with the TG or Budbuilt skidplate- its 3/8 plate steel -It wont let you down. Are you going to make a square shaft for the front?

[Peterbuilt84]

I thought about those skidplates, but the only thing is I'm running the rotated adapter so my rear case wouldn't line up right. That's the only reason why I haven't gone with one of those two.

Yea, plan on running a square shaft in the front.

[csb]

Right on. I have duals and only run one (bomb proof)tcase mount. I have a friend that also runs duals and has one (stock)tcase mount, and hes done Moab, Hammers, and the Con several times without any issues. We both run the mount on the rear case though.

[Peterbuilt84]

Good to know, thanks  The 4xinnovations crossmember only uses 1 mount, which I wasn't too sure about. If it needs another it looks easy enough to add another. Now I get to use my hf kinker to make the crossmember 

This is the crossmember I was going to copy, if anyone is wondering.

[SloCrawler]

I like it

[santa cruz crawler]

Looks good!

[Peterbuilt84]

Thanks guys! Unfortunately that's not my truck, just a pic I stole of what I want to do    

[4RunnerChevy]

Gimme Dims and the tube, i'll bend it for you. I can input it in the software so you can see it before its bent.  I just wanna see this thing hit the road.

[Peterbuilt84]

Thanks for the offer Kevin! I don't have any tube though. I was just going to use sch 40 to save on cost since tube is $3+ a foot, but I don't even have the pipe.

[Peterbuilt84]

Here's the progress on the rust. I put some fiberglass filler on the smaller holes. Just need to sand those down and paint the window frame.

Passenger side





Driver Side







Bottom Rail

[4RunnerChevy]

That will work 

[redrocket93]

Cool build. Great job on the rust repair.

[Peterbuilt84]

Thanks guys! It wasn't as hard as I expected, just time consuming. It's going to be nice to not have any more leaks.

[Peterbuilt84]

Pretty much finished up on the rust repair, just need to clean and paint it with some Por-15. I used some fiberglass filler called Long N' Strong on the smaller rust holes, highly recommend it. Just spread it over and sand it down.

On another note I found out I have to take my cases out again. I didn't grease the input/coupler when I put together my duals which can cause fretting. Shouldn't be too bad though, don't have to tear them down just pull them apart. Hoping to get everything done tomorrow.

[Peterbuilt84]

Well, found more rust    It's right inside where the passenger side cowl empties out into the inner fender. I noticed a bunch of leaves and junk in the hole so I decided to try to get it out. Once I started to get it clean I noticed  a lot of rust. Seems like the leaves blocked the hole so the water would just sit there after it rained. Figured this is another place where water was getting into the cab.

I was thinking about just blocking off the whole side, maybe with some waterproof foam. I was thinking the stuff that in the can Any suggestions are welcome. I don't really want to tear out all the heater lines and junk to get back there though.

[4RunnerChevy]

If your gonna go that route, try spraying or brushing rust converter in all the affected areas.  The stuff we use at work, does real well, and you know how we are fighting rust every day.

[Peterbuilt84]

Definitely, rust sucks    I pretty much put Por-15 on everything I have to paint to fight the rust. I should have mentioned the problem is a big hole caused by the sitting leaves, I can probably fit a couple fingers through it if I reach behind the dash. That's why I was thinking about blocking it off, so I don't have to fix the hole  

[4RunnerChevy]

For your rig, I would just block it.  Its a wheeler, not a show piece. 

[Peterbuilt84]

That's exactly what I was thinking. If it was nice to begin with it would be one thing, but at this point I just wanna go wheelin.

[4RunnerChevy]

That's exactly what I was thinking. If it was nice to begin with it would be one thing, but at this point I just wanna go wheelin.

Thats funny.

If its nice to begin with, then it has not been wheeled !

[Peterbuilt84]

Forgot to update this before I left, I'm back at school now. Got the windshield put in before I left, not much else besides that though. I have a pile of parts when I get a chance to work in it though. New driveshaft came in, found a good deal on some 4runner rotors and calipers so I can use the fror taco brake kit I have. Also picked up a spartan locker for the front. Found some rear disk brake brackets on pirate for a really good deal, so I'm going to put my front rotors and calipers on the rear when I finish the front up.

I still have to put the dash back together, build a front driveshaft, put in the t-case brake and figure out how I'm going to do the dual case crossmember. I should be ready to wheel by next season...hopefully  

[Peterbuilt84]

Small update. Got my front axle taken apart to put in the new brakes, but I forgot I needed to get the hubs turned down so the rotors will slide over Overall with family and stuff I didn't get as much done as I would have like to. Should start making progress in a couple weeks when finals are over Hoping to get everything done for a new years run at Johnson Valley 

[Peterbuilt84]

Well, found more rust    It's right inside where the passenger side cowl empties out into the inner fender. I noticed a bunch of leaves and junk in the hole so I decided to try to get it out. Once I started to get it clean I noticed  a lot of rust. Seems like the leaves blocked the hole so the water would just sit there after it rained. Figured this is another place where water was getting into the cab.

I was thinking about just blocking off the whole side, maybe with some waterproof foam. I was thinking the stuff that in the can Any suggestions are welcome. I don't really want to tear out all the heater lines and junk to get back there though.

Anybody have any ideas or suggestions on this? I just want to block it it off, but not cause more problems later.

[*** YELLER ***]

4X Inovations crossmembers are great and If you add a metal plate to the bottom thy make a great tranny/ transfer case skid, trust me lol

[Peterbuilt84]

4X Inovations crossmembers are great and If you add a metal plate to the bottom thy make a great tranny/ transfer case skid, trust me lol

Haha, I'll take your word for it. I definitely plan to add a plate to the bottom, did you just weld yours?