4runnerchevy's Exo

[4runnerchevy]

I am about to do a little exo. Anyone on this site gone there.

[Good Times]

Mossyrocks (Brad) for starters :)

I think Ike has a partial exo?

[Tankota]

I remember a while ago I found a thread of just exo pictures, I think it was on pirate.

[4runnerchevy]

Mossyrocks (Brad) for starters :)

I think Ike has a partial exo?


Gotcha, how could I not remember that. Anyway the DOM tubing is on the way.

[04 Rocko Taco]

There is a lot of good information on the Exo Thread on Pirate, I'm sure you have lurked over there though. As for over here, I think Brad would be the guy to talk to. May also want to hit up Heath (IntrepidYota) knowing he pretty much has a tube frame now, albeit his is all poop pipe, but the physics and engineering should all be the same...

[4runnerchevy]

Thanks for the reply, I am all over Pirate, and actually I did a crude rear drawing. I had our QSI look at it and he says its sound ( I sometimes build parts for his salt flat stuff ). I am using 1 3/4 .188 DOM for the main cab hoops. I will be probably using 1 3/4 HREW .125 for the fenders and bracing. Just working out mounts or replacing my tube rear gate. The rear gate is a body bount thing and will not work as part of the exo. I also gotta accomodate my vinyl top, and real doors.

I'll get a pic as soon as I can figure out how to export it to a usable format.

[Whitey]

If it's on your comp. Just save the image as a screen capture.

[slosurfer]

If it's on your comp. Just save the image as a screen capture.


I bet it's drawn on a Hot Dog on a Stick napkin. :flipoff:

[4runnerchevy]

I bet it's drawn on a Hot Dog on a Stick napkin. :flipoff:


Actually its crayon, on poster board, my daughter designed it. :flipoff:

[reggie 00]

I bet it's drawn on a Hot Dog on a Stick napkin. :flipoff:


Actually its crayon, on poster board, my daughter designed it. :flipoff:


Is that why your buddy approved it cause it was actually designed correctly??

[4runnerchevy]

He's the 75 year old engineer, who's been building chassis forever, I am not. If he thinks its strong then I have to respect his opinion.

No I cannot capture the image, for some reason I can't bring it up at home. When I start I will take pics.

Yes I am watching this thread on Pirate.
http://www.pirate4x4.com/forum/showthread.php?s=&threadid=95564&highlight=exo

Just thought I would try expand the tech around here, not just what kind of lights should I run, and will 31's fit my truck. My bad :flipoff:

[slosurfer]

Well, I for one, can't wait to see what you come up with.

[04 Rocko Taco]

Looking forward to it Kevin, and who knows, if you make it really pretty, I may come out and give you the honor of doing mine. :)

[4runnerchevy]

Looking forward to it Kevin, and who knows, if you make it really pretty, I may come out and give you the honor of doing mine. :)


Thanx Chris, I don't think the left coast is ready for you !


I am also looking forward to seeing what this guy is gonna come up with. :headscratch:

[4runnerchevy]

The tools:

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/hood.jpg

http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2412.jpg

Rear hoops in the rough.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/RearHoopsRough.jpg

Cools tool.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/tool1.jpg

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/tool2.jpg

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/tool3.jpg

More pics to come. As parts get done they will be blasted and painted with a semi black, masking any weld points. My aim is to tie it into, my front and rear bumpers, but allowing the front to be removed. My current front bumper will soon be replaced, with a tube setup/winch mount/stinger. My front bumper must remain removeable, cause the radiator/mount assembly is easy release, to allow the motor to be removed through the front (this becomes on issue with cherry pickers and tall trucks). Its a slow process, with all my other crap going on, so updates will be slow.

[corax]

My front bumper must remain removeable, cause the radiator/mount assembly is easy release, to allow the motor to be removed through the front (this becomes on issue with cherry pickers and tall trucks).

another down-fall of a cheby engine swap . . . the need to keep easy engine removal in mind when building :flipoff:


looking forward to the pics though . . . if you don't already have a pipe notcher or access to one I would recommend an Old Joint Jigger Pipe Notcher knock-off (just maybe not in purple)
http://www.northerntool.com/images/product/images/152392_lg.gif

ebay (http://shop.ebay.com/?_from=R40&_trksid=m38.l1313&_nkw=notcher&_sacat=See-All-Categories) prices aren't bad and mine has held up for years already with no noticeable slop in it (3 bumpers + 1 flatbed with rear cage)

[4runnerchevy]

We have a 45 ton iron worker, with notchers for all tubes and pipes to 2". It also punches, shears and brakes. Good tool though Keith. I also have the joint jigger, like the one shown.

[Cebby]

Pic of the Ironworker!

[4runnerchevy]

Oh its a very cool little number, I'll take decent pics when the wife gets home with the camera, and I am at the shop. Its a $4000 number, but with the tooling, about $4000 extra. Great for production, It shears 8"x1/2" thick solid, and will just about brake it, maybe 3 bumps.

[Tankota]

At this past SEMA show there were several manufactures showing various ironworker type rigs. On one, this guy was chomping half dollar sized plugs out of 1/2" plate like it was cardboard. Those thinks are sweet. Really dig the tubing notch capability too.

[4x4mike]

We have a 45 ton iron worker, with notchers for all tubes and pipes to 2". It also punches, shears and brakes. Good tool though Keith. I also have the joint jigger, like the one shown.


Must be nice. I have resorted to go old school and use brute strength in my projects. Some day I'll hurt myself but until I can have access to an iron worker...

[4runnerchevy]

I do have to thank my job for 24/7 access to the fab shop. It by far exceeds my shop at home.

The Iron Worker
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2405.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2406.jpg

The Mill
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2409.jpg

The Lathe
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2408.jpg
Yes that is a 1920's model A truck differential, I just finished a setup on.

Cold Saw, for precision cutting.
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2403.jpg

Other Stuff
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2410.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2413.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2411.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Tools/100_2407.jpg

[4x4mike]

24/7! Sweet. If I had access to all of that I don't think I'd come home much. I could get all kind of projects done and I'd probably be money ahead.

[4runnerchevy]

Some parts tacked in.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Exo1.jpg

[Tankota]

Nice to see it getting underway already.
What sort of material is that stock roll bar made of? Is it strong enough to become part of your exo?

hehe... I think the date in you camera is off...

[4runnerchevy]

Nice to see it getting underway already.
What sort of material is that stock roll bar made of? Is it strong enough to become part of your exo?

hehe... I think the date in you camera is off...


That stock thing in question is metric, I have not measured its thickness but its around 3/32, but almost 2" diameter. When the other tubes are in, it really wont be an issue. It will all, tie into the exo cab hoop. Some of the stuff you see, tied into the stock rear bar, is old stuff, the new stuff is the raw steel. I will have to make another tube gate in the rear, I have an idea for that. Right now its work from rear to front. Portions will come back off for welding and painting as I go.

By the way that stock rear bar, has been in a couple of flops.

I'll get some shots this weekend when I roll it out of its berth and yes the date will be fixed.

[Tankota]

Thats cool, I always wondered how those sock roll bars would hold up in a flop. I know I've seen the cages on wranglers collapse after a mild roll before.

[4runnerchevy]

Pics, still working the rear.
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Side1.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Side2.jpg

[slosurfer]

sweet! :thumbup:

I may have missed this earlier, but are you just planning on making your own bikini top for the back?

[4runnerchevy]

I have a soft top, and the wife will be making me a new one.

[Scuba]

Dang that it sweet ! Nice work so far, Cant wait to see the rest ! :clap:


:bling:

[4runnerchevy]

After some though I decided to make a new tailgate, that ties into the exo. I am going to start with the bottom tube and make some spring loaded pins.

I made some pin recievers for the exo and some spring loaded pins for the gate.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Insert1.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Insert2.jpg
Excuse the grease, on the pins.
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Insert25.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Insert3.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Insert45.jpg

And the bottom tube done.
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Rear2.jpg

Rear from the side.
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Rear1.jpg

[4runnerchevy]

Ok, I started roughing in the gate.

Rough Gate
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/roughgate.jpg

Gate down
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/down.jpg

Gate with Toyota mock-up
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Platemock.jpg

cheers :drink:

[CJM]

Cool design, I like your latches.

[4runnerchevy]

After making the bottom pins, I thought about making bumpstops with progressive springs.

[CJM]

After making the bottom pins, I thought about making bumpstops with progressive springs.

wonder how that would turn out?

[Mossyrocks]

good job man. and Im jealous of your tools... hehe

[4runnerchevy]

good job man. and Im jealous of your tools... hehe


Just think if you crossed your mad fab skills, and beautiful welds with the those tools.

[04 Rocko Taco]

Looks great Kev! digging the tailgate!

Want to send me yuour old one? :angel:

[4runnerchevy]

Sorry Chris, I had to steal some stuff off it. lol

[04 Rocko Taco]

dang. I liked the looks of that thing. Guess I'll just have to build one. :)

[4runnerchevy]

lol, its not done yet. I am still gonna put 1 more tube and a stainless piece behind the plate. Maybe Saturday

[waskillywabbit]

Very nice spring loading doohickies. Got any more detailed pics of those? What parts did you use?

:guitar:

[4runnerchevy]

I'll take some pics of it dis-assembled. I used 4" of 3/4" 316 stainless rod. The bushing were machined from oil impregnated (oilyte) bronze. I used a 3/4x3" spring (unsure of its rating). The knobs are held on by studs, which is also the pin which keeps the assembly together (remove knob to service). The knobs are hard plastic, with a 5/16 stainless threaded insert (I have a bunch laying around). I tig welded the inserts in with silicon bronze, cause of heat issues.

Detailed pics soon.

[4runnerchevy]

Finished the gate (more or less).

Heres a disassembled pic of the pin, in question.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Breakdownofpin.jpg

and two of the gate.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/Finished.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/finished2.jpg

I was gonna put a UY sticker, next to the plate, but the one I have is the wrong color (black won't show). Oh well !

cheers :drink:

[4runnerchevy]

Well after some thought I decided to built a front tube bumper. My modified smitty has to go, cause it would be extremely :gay: to tie it into the exo. Since my exo has to tie into a removable front bumper, I decided to make it out of the same material. Main bumper tube is bent and ready to get fitted to front.

The main cab hoop is also nearly done, ran into some problems with gaps between cab and bar. My passenger side has been flopped so the gap will be different (very little). I decided to go with a symetrical hoop instead of making it custom for each side.

I'll post pics as soon as progress is made.

:drink: cheers

[slosurfer]

Cool, I can't wait to see pics. :thumbup:

[04 Rocko Taco]

Hey buddy, looking great, glad to hear the front is coming along. Got any more detailed pics of the latches at the top of the gate?

[4runnerchevy]

It seems I don't have detailed pics of the spring latches. I will take a detailed pic of the latch, and rubber lined stop. I'll post up tonight.

[4runnerchevy]

Ok Chris, heres the latches, and no I havn't figured out the macro setting.
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0001.jpg
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0003.jpg

No Bumper
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0005.jpg

Bumper lower half
http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0006.jpg

More tomarrow, making the mounting brackets for the bumper.

[4runnerchevy]

Progress !

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0001-1.jpg

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0002-1.jpg

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0003-1.jpg

[corax]

Nice :thumbup:

I like the bumper, are you going to run some pipe up the A-pillars?

[4runnerchevy]

Oh, its not done. I am gonna cap the roof, I already have some of it done. I am also gonna run tube on the bottom of the windshield and tie in the fenders.

I also built and welded in this rear bar for my 4/5 point harnesses.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0001-2.jpg

[04 Rocko Taco]

Looking good Kevin! I like the front bumper, I should be getting my cage built very soon. I want to talk to you sometime about your lack of rear seats, and if you have done any other mods back there. I am looking to try and put buckets back there to save a little space, over the bench seat.

[corax]

I also built and welded in this rear bar for my 4/5 point harnesses.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0001-2.jpg



For the harnesses, are you going to do a 3/4 wrap over the top of the bar and around to the mount points?

[4runnerchevy]

Looking good Kevin! I like the front bumper, I should be getting my cage built very soon. I want to talk to you sometime about your lack of rear seats, and if you have done any other mods back there. I am looking to try and put buckets back there to save a little space, over the bench seat.


Ok, the fuel tank is under that tire.





I also built and welded in this rear bar for my 4/5 point harnesses.

http://i203.photobucket.com/albums/aa116/4runnerchevy/Exo%20Cage/PICT0001-2.jpg



For the harnesses, are you going to do a 3/4 wrap over the top of the bar and around to the mount points?


I am keeping my shoulders 0-15* The hardware allows for pivot, so I will use it. I am working the rest out, just got to be right !

[corax]

I am keeping my shoulders 0-15* The hardware allows for pivot, so I will use it. I am working the rest out, just got to be right !


I was thinking more about the harnesses pulling on those tabs sideways - versus with a 3/4 wrap over the top and mounting on the front pulling them into the bar and trying to twist the bar (less likely to give, I would think)

[4runnerchevy]

I am keeping my shoulders 0-15* The hardware allows for pivot, so I will use it. I am working the rest out, just got to be right !


I was thinking more about the harnesses pulling on those tabs sideways - versus with a 3/4 wrap over the top and mounting on the front pulling them into the bar and trying to twist the bar (less likely to give, I would think)


I think the hardware, allows for the belt to pivot, so it doesn't tangle. 0-15* is the amount (suggested) below my shoulders, and I seriously doubt those Beams tabs or the tube they are welded to will ever go anywhere. I'll post up a pic of them mounted, soon. I am going by the instructions.

Here
http://www.crowenterprizes.com/Pages/Install.html

[Seanz0rz]

if youre putting enough force on those seat belts to break a tab off, i think you have MUCH bigger concerns than the tab breaking off.

that being said. im kind of confused. shouldnt that bar be about 9-12 inches higher to get it in line with your shoulders (or up to 15* below), about the point where the padding starts on the roll bar? and those tabs should be facing forward in the line of action on the belt?

im probably wrong, just clarifying. exo looks good. thats about what i want mine to look like with the tubes over the wheel wells.

[AxleIke]

Looks Awesome!!!

Great work.

[4runnerchevy]

if youre putting enough force on those seat belts to break a tab off, i think you have MUCH bigger concerns than the tab breaking off.

that being said. im kind of confused. shouldnt that bar be about 9-12 inches higher to get it in line with your shoulders (or up to 15* below), about the point where the padding starts on the roll bar? and those tabs should be facing forward in the line of action on the belt?

im probably wrong, just clarifying. exo looks good. thats about what i want mine to look like with the tubes over the wheel wells.


Remember it is a 4/5 point harness, I am not dependent on 2 of the points. As far as the tabs breaking, those tabs are designed for the purpose I put them in. I have seen those tabs take far further abuse then I can possibly give them. My biggest fear would be the tube bending a little, but not a tab comming off or breaking. If the tube bends in a rollover then that is the least of my problems. Keep in mind that the seats are as far forward as they go in that picture. 9 inches would put them even or higher then my shoulders, and especially over the shoulders of my spotter (he is shorter).

[Seanz0rz]

yeah i guess it was just the angle of the picture, but that tube look really low.

[4runnerchevy]

yeah i guess it was just the angle of the picture, but that tube look really low.


Yeah its decieving. The harness came with webs to go to the floor, but after talking to the race guys, they seem to think they should be mounted the tube way (something about compression). I dunno, but after flopping myself, this is way better then the factory belts. They are off road only in Cali, so I am not looking at a 75 MPH crash.

[bigarms23]

i definately like the new front bumper over your old smitty built

[4runnerchevy]

i definately like the new front bumper over your old smitty built


Yeah, the runner is way different since you were down here. The smitty sucked, modifying it all the time, and shear weight. Off topic, HH run got changed if you can make it!

[bigarms23]

still have to work but be down still thinking first week of may hopefully maybe we can run to hollister than

[4runnerchevy]

Daniel Pm'd