fuster's runner build continued from the garage rig pic forum... [Archive] - Page 2

YotaFun

08-25-2007, 11:12 PM

BTW Where do you live?? LOL!

Oh Fuster.

Now I am really jealous...

Your getting the pick up I want, and you have a 1st gen Runner with a SFA...

You sir are living my dreams, and you know what, your are probably the best man to do it too lol!

We just moved to Utah where I found my next project. Below is a 1981 sr5 pickup with air. I just made an offer on it to the original owner this afternoon. He accepted, but needs to consult with his wife about it tonight.

http://i40.photobucket.com/albums/e201/1fustercluck/DSC022571.jpg

:hillbill:

waskillywabbit

08-26-2007, 06:54 AM

Living a dream is 10% inspiration and 90% persperation.

We had a saying in Engineering school at The University of Alabama, tongue in cheek, "Persistance always beats Resistance" :D

Nice acquisition fuster...did you see mine I got Friday?
http://www.wabfab.org/projects/1985pu/85pu1.jpg

:guitar:

fustercluck

08-26-2007, 04:38 PM

Nice! I guess I'm with Intrepid, Does this one get dented? :hillbill:

YotaFun

08-26-2007, 07:53 PM

Intrepidyota

08-27-2007, 02:31 AM

So does THIS ONE get dented? :D

Ya know, Intrepid, given the content of your boulder bashing threads, and the recent chiding and encouragement to follow your lead, I don't think it's a stretch to say that you have a sadistic side......:hillbill:....and yes, this one gets dented :D :D :D :D

:lol: :lol: :lol:

YAAAAAAAAAAAAAAAAAAY!!! :clap:

I wheeled this weekend and only got one very minor dent, I am practically reformed! :laugh:

slosurfer

08-27-2007, 09:22 PM

Fuster, I think I may have found your next project. 1965 Toyota Stout I found one local, haven't looked at it yet, but I really only have trade work to offer the guy for it. Unfortunately for me, he was a mason, so in turn does his own tile work. :chair: Supposedly it has a dent, it runs (the guy said he couldn't believe it but it started right up, and it may need some front end work (he wasn't sure, he just thought one of the tires looked a little off, not much to the front end though) I haven't looked at it because he said he got tired of going out there just for folks to look at it. I was really hopeing that he needed some tile work done. :(

For those who don't know what a Stout looks like, here is a pic: (I don't have any pics of the one that is local to me)
http://i38.photobucket.com/albums/e113/slosurfer27/67_toyota_truck_500.jpg

Here is some pics of a restored one
http://www.toyotaclub.org/featured67stout.html

Another restored one
http://www.gasolinealley.com.au/toyota_restoration.shtml

fustercluck

08-27-2007, 09:41 PM

Now THOSE are rare.....

When I was kid, I saw one at a red light. Would love one if only for the nostalgia...

fustercluck

08-27-2007, 09:42 PM

amgraham

09-06-2007, 11:53 AM

Sooo Fuster... Is that runner still sitting there with the custom tinted windows? :D

fustercluck

09-06-2007, 10:30 PM

Yeah, I have to say that some things have developed on the home front which ahve delayed my progress and ended the vacation mode I was in. Mrs Fuster's father, a WWII combat veteran and hero slipped from mortality last week and we've been occupied by the events that unfolded as a result. Not to plunge this thread into morosity, but my father-in-law was such a good man that our loss has eclipsed about every other concern we previously had. It would take chapters and pages for me to fully describe his life; a feat for which most would little patience and I would have even less capacity....suffice it to say that I'm honored to tears to be a part of his family.

callmej75

09-06-2007, 10:34 PM

Very sorry to hear of the loss Fuster...My hats off to the fallen vet.

amgraham

09-07-2007, 05:41 AM

Definitely. Condolences to you and your family Fuster.

04 Rocko Taco

09-07-2007, 06:11 AM

As i mentioned earlier, my thoughts and prayers, and those of my family, are with you and your family man!! I feel greatly for the loss of someone who holds such esteem in your eyes. He must have been a truly great man!

breknraj

09-10-2007, 10:23 PM

My condolences to you and yours, Fuster.

As you are obviously aware, the Runner will still be there, after you have looked after your family - kudos to you.

fustercluck

09-15-2007, 01:10 PM

Thanks y'all, for the kind wishes and thoughts. I've had to work out of town for a couple of weeks on a remote assignment and have been incomunicado. Will be back in a week. Looking forward to re-assembly.....

fustercluck

11-13-2007, 05:09 PM

So today, after a 2.5 month pause, I bled the brakes, re-connected the fuel inlet and vent hoses, had the fuel door lock cylinder re-keyed along with the tailgate window switch cylinder.

It took about two hours to empty the bed of all of the parts and fasteners I had stored there for the move from school. I also had to use a solvent to remove the adhesive residue left by the tape I used to dry-in the windows while the runner was sitting.

Now it seems after such a lengthy hiatus, I have to spend time discovering how things are to be re-assembled. I have lost the advantage of recent experience and am left with a feeble memory and a pile of parts. This will likely cause some delays and misatkes. Such are the consequences of chronic procrastination and late middle age combined; a perfect storm for Keystone Cops proceedure.

Anyway, tomorrow the plan is to reassemble the dash, driver door and maybe the cap windows. We'll see how it goes. Pics are imminent.....

Seanz0rz

11-13-2007, 05:18 PM

bout fricken time!!!!! we demand pictures!

fustercluck

11-13-2007, 05:33 PM

:hillbill:

YotaFun

11-13-2007, 05:52 PM

Please Fuster?!?
I am in love with this 4Runner!

slosurfer

11-13-2007, 07:36 PM

Spend more time wrenching and less time bumping old thread at TOF. :flipoff:

On a side note, it is pretty dang funny to see some of those old ones still up in the new posts today.

fustercluck

11-13-2007, 08:53 PM

Spend more time wrenching and less time bumping old thread at TOF. :flipoff:

On a side note, it is pretty dang funny to see some of those old ones still up in the new posts today.

:flipoff: Yeah, I'm pretty pitiful...

fustercluck

11-14-2007, 10:00 PM

Today I cleaned the crust of body dust/monsoon storm spray from the entrails of the dash. When I stripped the interior, my intention was to cover the exposed components, but as this project advanced and my patience ebbed, I neglected to cover the ventilation and harnesses. I paid the price of impatience this morning.

After some housekeeping, I reassembled the ducts, harness, gauge cluster and dash. Fortunately, I had the presence of mind to categorize and label all of the hundreds of fasteners in zip lock baggies. That made the process more expeditious.

I wrestled with re-installing the fuel door lock and remote release tang. I had removed it in haste and forgot to study how it's pieces were oriented. D'oh! I lost twenty minutes on that.

I poured a couple of gallons of fuel into the tank and capped it off for the first start up since April 07. I inserted the key, turned the switch and.....

...nothing. The battery is as dead as Air America (hehe.) It is charging for tomorrow's second attempt.

At this point, there are about 50,000,000 little fastener grommets that I have to buy from the dealer because they were so brittle that they pulverized upon disassembly. The sum of those parts plus a new antenna, new rear window felt (in and out), new front window felts (in/out) and some miscellany, amounted to $250.00 at the dealership. I was stunned to have paid 30.00 for the hood mounted washer nozzles alone. :cry:

I took some more pics, but you'll have to wait until tomorrow. The camera is still out in the garage and I've already sat down for the evening... Help, I've fallen and I can't get up!!!!

fustercluck

11-15-2007, 08:58 AM

Erich_870

11-15-2007, 10:24 AM

Without the incriminating confession of a full accounting, I'd say I'm into this build about 2800.00. Of course I'll deny it if that number is used by my controlling legal authority as leverage against any future firearms acquisitions. :hillbill:

I've implemented a new technique with my "controlling legal authority" to prevent leverage against any future tool or project supply acquisitions. I call it "the lesser of two evils". Basically I purposely spill the beans about a tools purchase price, but I multiply it by a large, but almost believable factor. She reacts to the high price and then I calm her fears by telling her the real, lower price. I only expect it to work for a limited time and it helps that everything is more expensive up here, but I should be able to keep my tool box growing for a little while longer :king:

Erich

fustercluck

11-15-2007, 02:21 PM

That's brilliant! First, condition with severity and then soften with reality. It's like good cop/bad cop only without all those body blows...:D I'm stealing this for future reference.

Well I haven't been very productive today. Mrs. Fuster's maldiction of a car got another flat tire and I've been dealing with the ramifications from that. I do have the previously promised pics and comentary.

Below is a pic of the dash reassembled complete with my pawn shop Sony stereo (CD player doesn't work, but I only listen to AM radio anyway:D). Notice the red overspray on the brown trim at the door pillar. This is why full disassembly is important for a thorough job. The passenger side vent is not fully installed yet. It is such a pain to remove that I am reluctant to comit until I know I am ready. Down on the driver side floor, I installed a dead pedal that I scavenged from another runner a year ago anticipating this resurrection.

My hood is shiney...:hillbill:

http://i40.photobucket.com/albums/e201/1fustercluck/Picture014.jpg

fustercluck

11-15-2007, 02:22 PM

Oops gotta go for a second...

Cebby

11-15-2007, 04:02 PM

Oops gotta go for a second...

Tease.

fustercluck

11-15-2007, 04:56 PM

Okay I'm back. I had an appointment that I forgot...

I'll try various solvents increasing in degree of chemical strength until I find the appropriate one. It's just annoying to have to do it...I'll start with your recommendation for alcohol.

Part of reassembly involves used parts that regardless of cleaning, are shabby. Below is an example. This is the grill and head light surrounds as they were. These were scrubbed and dried.

http://i40.photobucket.com/albums/e201/1fustercluck/Picture007.jpg

Dang. I've been called to dinner. Be right back.

fustercluck

11-15-2007, 05:06 PM

This is how it looks now. The chocolate milk stains on the wall are what you get when the younglings take the trash out unwillingly.

I still have to touch-up where the paint breached the masking, but you can see the improvement.

http://i40.photobucket.com/albums/e201/1fustercluck/Picture015.jpg

fustercluck

11-15-2007, 05:22 PM

Pictured in the following is how I finished the grill parts. On the left is a light surround which has been sanded with 400g paper and washed.

http://i40.photobucket.com/albums/e201/1fustercluck/Picture008.jpg

Below is a pic of one of the center grill mounting towers. It was broken and would rattle as I drove. The gray goo is JB weld. Normally, a thin coat over a clean break would re-break shortly after installation. I used the concrete/rebar theory and imbedded a layer of aluminum foil tripled over with JB weld between each fold and over the top. I think the two components, while impotent individually, combined will make a permanent repair.

http://i40.photobucket.com/albums/e201/1fustercluck/Picture010.jpg

This is the surround with silver hammered paint applied.

http://i40.photobucket.com/albums/e201/1fustercluck/Picture009.jpg

Now we are masked to receive the satin black.

http://i40.photobucket.com/albums/e201/1fustercluck/Picture011.jpg

fustercluck

11-15-2007, 05:30 PM

Well here's my dilema: I can't find one of the door handles I as going to use. I have two others, but they are the chrome SR5 parts. I don't mind chrome, but it's not what I had planned. If i go with the black ones, I have to scrounge another one. If I use the chrome, I can finish the doors tomorrow.....Dang. What do y'all think?

Black...
http://i40.photobucket.com/albums/e201/1fustercluck/Picture012.jpg

Chrome...
http://i40.photobucket.com/albums/e201/1fustercluck/Picture013.jpg

Seanz0rz

11-15-2007, 05:54 PM

that chrome paint fuster on that handle? that stuff has a tendency to NOT ever dry, and is highly susceptible to fingerprints being embedded in the paint. just FYI. maybe they have improved it over the years.

ok edit, i need to read stuff first.. im going to leave that there for future info though.

as for chrome, is there any other chrome on the vehicle?

Cebby

11-15-2007, 06:13 PM

Find another black one. I'll bet Wabbit has one.

If he doesn't, I think I can get my hands on one for you.

fustercluck

11-15-2007, 06:24 PM

Well that's just it. I have blacked out most everything. I even debadged the tailgate before paint. The handes are factory chrome as well as all of the key cylinders. I suppose that if the cylinders are chrome (I can't change those), the handles could be and still be consistent...

I think I'll go ahead and install the chrome and if I hate it, I'll change later. I don't want to waste another day on pseudo-important homodesigner stuff :hillbill: (not that there's anything wrong with that....)

fustercluck

11-15-2007, 06:26 PM

Edit: Thanks Cebby. If you find one, I need the driver side.

waskillywabbit

11-15-2007, 07:39 PM

All the extra door handles I have are chrome. :D

:guitar:

Seanz0rz

11-15-2007, 08:04 PM

fuster, juts get some satin paint and paint the handle :hillbill: :flipoff:

fustercluck

11-16-2007, 05:52 PM

I mounted the grill and side marker/blinkers this morning and spent the rest of the day reassembling the doors and rear topper windows. Right now I'm having a break to see if I'm un-banned yet :hillbill:

I took some pics for later. Things are coming together nicely....

fustercluck

11-16-2007, 09:07 PM

Just finished installing the two harnesses; one for each rear fender to the tail lights. I had to remove the original one since it was cut at the door sills instead of being unplugged at the pigtails. That allowed me to put the tail lights in. I'll post the pics in the morning.

Tomorrow I'll work on the slider windows and the dreaded Tailgate window. I need to have this truck 'dried-in' by Monday when the snow storm comes.

After that, all that is left is seatbelts, rear seats, headliner and misc. int. parts, some minor ext. knick knacks and if I feel like it, finish cutting and buffing. I still can't get it to start, so it looks like I'l have to jump it. I hope the battery isn't ruined...

slosurfer

11-17-2007, 08:22 AM

so it looks like I'l have to jump it.

This is what yours will look like being jumped! :D

http://i3.photobucket.com/albums/y93/expatozzie/Pismo%20Beach%20Oct%2007/PismoUltimateYota015.jpg

On a side note, I still have not been able to figure out who that guy is and I was starting to think that you made an appearance at Pismo (similar color to yours)

fustercluck

11-17-2007, 07:37 PM

Haha Slo, If I ever jumped ANYTHING like that, there would be an expletive laced caption to read. :hillbill:

Well I reversed myself on the promise to post pics this morning. It takes awhile to do it with narrative so I thought I'd do it early while the garage warmed up a bit....I did not anticipate sleeping in as long as I did this morning. D'oh!

Today I located the parts for the slider windows and cleaned them. They have been kicking around throughout this whole project and had a liberal sediment of various contaminants on them. They also never have operated smoothly, so this was as good a time as any to resolve their issues. While they were apart, I repainted the metal in satin black. After the finish cured, I put them together and mounted them with this heinous black adhesive I got from Techniglass (those guys were a great help by-the-way...).

While the sliders were curing, I began the tailgate assembly. I have dreaded this aspect since June when I removed all of it's components for paint. The efffort and frustration involved in separating the glass from the regulator arms and then the motor assembly from the shell, was a distant but poignant memory. I was relieved to find that it only took me 20 mins. to reconstruct the tailgate; though I left the window off of the regulator arms for now.

I repainted and affixed the cab pillar trim and replaced the inner fender liners. I also put the door mirrors on. I was going to buy new ones because when we were cutting the old bed off, some of the hot metal sparks hit the glass and pitted them. They looked fairly bad and I assumed they'd be ruined, but when I cleeaned them up, the weren't that bad. They still have a few scars. If it bothers me later, I'll get new ones.

I promise cross-my-heart-hope-to-die-stick-a-needle-in-my-eye that I'll post pic and monologue tomorrow.

Here's a few to hold you over...

http://www.freedomworks.org/blog/wp-content/uploads/2007/06/hillary_vader21.jpg

http://www.all4humor.com/images/files/Scary%20Hillary%20Clinton.jpg

http://uglydemocrats.com/democrats/United-States/Hillary-Clinton/hillary-bill-clinton.jpg

http://poljunk.gloriousnoise.com/images/hillary.jpg

http://img.slate.com/media/1/123125/2090808/2114578/2122508/050728_bi_HillaryClinton_ex.jpg

http://www.clevelandseniors.com/images/quiz/famous/bill-hillary-clinton.jpg

http://www.passionateamerica.com/pictures/The_Real_Hillary.jpg

http://carryonamerica.com/photosforblog/hillaryfright.jpg

fustercluck

11-18-2007, 06:52 PM

Well it appears my battery ist kaputt. It wouldn't even turn over with a jump. I checked all of the cells and they were borderline good/fair condition. I'll have to remedy that tomorrow. I just did some detailing today and sort of cleaned up after myself in the garage so we could get other cars in for the storm tomorrow. As it sits now, the runner is completely dried-in. This is first time it has been entirely insulated from the elements since last April. Now when the wind blows or the snow flies, I don't need to worry.

Below is a pic that shows the driver door at 50% completion. While it looks skeletal, there is quite a bit of time invested here. Each of the many parts have to be placed in the proper order, or they interfere with the other parts...it's Tetris. The lock cylinder goes first, then the handle, then the latch mechanism and release lever rod goes in. At this point, the vent window is placed but not secured. The window guide extension is secured over the latch mech. and the rubber guide molding is installed halfway. The glass goes in and gently rested at the bottom of the door. The vent window is then tilted back enough to insert the window edges into the guide rail on both sides. Secure the vent window by the tail screw and finish installing the rubber guide molding. Slip the window crank assembly into place around the tail of the vent window and slide the window up until it just clears the horizontal shaped center opening (see pic). Crank up the window regulator until just past the opening and parallel with the window bottom. Secure the glass to the regulator. That is half of the process to complete the door assembly and what is demonstrated in the pic.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner318.jpg

More to come...in 5 mins.

fustercluck

11-18-2007, 07:30 PM

Speaking of the window crank assembly, a word to the wise is sufficient: When lubricating the cog and gear assembly, note that the crank arm is spring loaded. If one turns the handle too far off the cog, the crank arm will be propelled down to his thumb knuckle and the live edge of the stamped steel will take a chunk of flesh out. As I hold the regulator arm, one can see the corporeal damage...it hurts worse than it looks so pity me.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner317.jpg

fustercluck

11-18-2007, 07:40 PM

As to installing the wing window, it must be turned sideways to allow the tail fastener tang to clear the gap provided. Simultaneously, it must be tilted back to clear the swept back rail of the door.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner321.jpg

Then it is inserted and turned parallel with the door while moving forward so that the springy thing at the bottom clears a sheet metal shelf inside the door shell

http://i40.photobucket.com/albums/e201/1fustercluck/85runner322.jpg

Once installed completely, there are three screws hidden under the weatherstrip that finish off the assembly. You can kinda see where they go in this pic

http://i40.photobucket.com/albums/e201/1fustercluck/85runner323.jpg

fustercluck

11-18-2007, 07:42 PM

At this point the door is finished. The wrinkle in on the upper portion of the skin should iron itself out in a few days.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner319.jpg

fustercluck

11-18-2007, 07:47 PM

I don't remember what I was trying to display here, but I do like the finised look of all of the elements together. As you can see, the painted portion against the rubber, glass and stainless steel is why I bothered to disassemble for paint. Had I not done that, there would be red showing here on the inside and Anthracite on the outside......eeewww!

http://i40.photobucket.com/albums/e201/1fustercluck/85runner320.jpg

fustercluck

11-18-2007, 07:52 PM

In this image I tried to display how I scraped the old adhesive off of the topper sliding windows to prep for installation. As one can see, I'm no photographer. The entire mounting surface had to be cleaned of the old adhesive. I used a utility razor and pulled it toward myself like a draw knife.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner328.jpg

fustercluck

11-18-2007, 08:02 PM

And here we have another colossal display of photographic prowess. In this failed attempt the intent was to display a bead of adhesive with a peak like a pyramid. The tube was cut such that it would dispense a bead with such a ridge. This ensures full contact with the mating surface and eliminates the likelihood of leaks.

This adhesive was so viscid, I had to use both hands to squeeze the gun lever. I even heated the tube to aid in flow. With both hands straining, I could only do about an inch before I had to ratchet the gun again. Dudes, that is grip fatigue...

http://i40.photobucket.com/albums/e201/1fustercluck/85runner327.jpg

fustercluck

11-18-2007, 08:05 PM

So now all of the windows are in and the doors are reassembled. This image is a bit blurry, but you get the idea. I think she's looking pretty good.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner324.jpg

fustercluck

11-18-2007, 08:07 PM

Here's the front. The sweatshirt is there to block the glare that I think is fouling up the camera shots.....'course it's prolly just journalistic incompetence :hillbill:

http://i40.photobucket.com/albums/e201/1fustercluck/85runner326.jpg

fustercluck

11-18-2007, 08:13 PM

This image shows the clean lines of the tailgate without the badges. I also blacked out the 'TOYOTA' on the key switch bar. No plate yet, as I'm waiting for the screw grommets to arrive from the dealer. The duct tape along the back window is temporary too. Again, I'm waiting for some parts to finish that aspect.

I should have her running tomorrow if I get time to handle the battery issue.

http://i40.photobucket.com/albums/e201/1fustercluck/85runner325.jpg

fustercluck

11-18-2007, 08:14 PM

Now for some 35" tires....:D

garrett

11-18-2007, 09:57 PM

:drool:

Intrepidyota

11-19-2007, 04:40 AM

Wow man! Looks great! Needs more dents... :tongueout:

Osiris

11-19-2007, 01:09 PM

I see some rocks to climb across the street!!!

callmej75

11-19-2007, 10:36 PM

Thats purty...that color almost matches my gun metal metallic powder.

Cebby

11-20-2007, 01:41 AM

B_E_A_UTIFUL as Jim Carrey would say (from Bruce Almighty)...

Outstanding work and great step by step images and text. Almost looks like you know what you are doing. :P

fustercluck

11-20-2007, 02:39 AM

Intrepidyota

11-20-2007, 04:42 AM

Thanks y'all. In the next couple of weeks i'll be designing and building afront and rear bumper. The form and funcion will be an ARB derivation, but with my own contortions to boot. I have a friend here who is not only a shooting buddy, but also a master metal-smith. He runs a machine shop and is supremely talented. Bumpers first, then sliders (that was a flagrantly incomplete sentance).

I'd like to finish them off in Rhino/Linex material. Can anyone think of why that would be unwise? I think that the bumpers, sliders and flares would look and function well with that stuff....what say ye?

Although I don't ever expect to see Wadada design elements in the Fustermobile, :tongueout: I would not use any sort of bed-liner on bumpers or sliders. I figure that these items are put on vehicles specifically to scrape on rocks and trees, so you will be peeling it back, it will look crappy, and it will be costly to touch up. Some nice rattle-can however, can be sanded and repainted. You will wear off spray paint if you step in the same spot on your sliders all the time, so perhaps use some bed-liner in a can just on the tops of the sliders where you step, and spray paint the bottom for easy touch up.

fustercluck

11-20-2007, 07:06 AM

Good point. Maybe bed liner on the top and sides? Hmmm. *scratches head*

Hehe. WADADA!!!!!!

Intrepidyota

11-20-2007, 10:21 AM

Hehe. WADADA!!!!!!

:lol: :lol: :lol:

fustercluck

11-20-2007, 06:26 PM

I fielded a PM from my friend Callmej75. He reminded me that he still does powder coating. For some reason I thought he had time only for his schooling. I'll be sending the bumpers, sliders and winch tray out to be finished by him. I hope there is a way he could sign his work so I can show it off:hillbill:

amgraham

11-20-2007, 07:19 PM

callmej75

11-20-2007, 07:20 PM

reggie 00

11-20-2007, 08:42 PM

PC sounds good. Would like to see how they hold up. Remembering J's argument about it i am sure they will do good.

On the Linex note. My buddy is a local dealer. He sprays gravel hoppers for local companies that have the big ol Semi pulled loaders. Pretty much makes the trailers last 3 or 4 times longer. They said with all the rocks going in and out it wears holes in the bottom, tried it years ago as a test and since then have all the trailers done. When done right the stuff is pretty hardcore. Cant see sliding along some rocks and what not doing anything at all to the stuff.

Simply because of my connection (see cost factor) i was planing on getting all my soon to be made/bought/etc armor/bumpers done. Time and money dictated my painting my sliders, will be upgrading here as money permits.

fustercluck

11-20-2007, 08:59 PM

fustercluck

11-20-2007, 09:05 PM

Well I have confirmation of my dorkness. I went to collect my battery from the Interstate dealer. They have a deep cycle charger that should have done the trick. Unfortunately, it wouldn't hold a charge overnight. Even though it was my fault, the dealer offered to warranty the batt. I accepted the offer and tomorrow morning I'll have a new Interstate battery for the runner. Now that's service.

Glad I didn't buy an Optima.

Seanz0rz

11-20-2007, 09:15 PM

slighly offtopic, but who actually sells interstate batteries?

fustercluck

11-20-2007, 10:20 PM

Around here they use retailers and repair shops. They keep a rack in the lobby kinda like those tasty little hostess donuts :D

amgraham

11-21-2007, 06:09 AM

Nah...I'm not dead...yet..LOL

I said mural, not memorial, dummy :P

callmej75

11-21-2007, 06:18 AM

Haha...usually its "In remembrance of..." but...the beneficial part would be he would have no tailgaters because my ugly mug would scare them back!

waskillywabbit

11-23-2007, 03:11 PM

The rig looks awesome but those nerf bars are killing me. :flipoff:

:guitar:

fustercluck

11-23-2007, 08:19 PM

The rig looks awesome but those nerf bars are killing me. :flipoff:

:guitar:

Hehe. All things in their time....line upone line. Wait til tomorrow. The most effextive mod will be done tomorrow. Pic is immanent...:hillbill:

fustercluck

11-24-2007, 03:23 PM

Okay, here is the mod I've been anticipating and patiently delaying the gratification until just the right moment. Ready?...

drumroll please....

http://i40.photobucket.com/albums/e201/1fustercluck/Pictureguns004.jpg

:clap: :P

callmej75

11-24-2007, 04:10 PM

You put us off for THAT?! Man...I just heard my bowels roll over...

Seanz0rz

11-24-2007, 06:41 PM

fuster, i believe this is how people get shot.

waskillywabbit

11-24-2007, 06:49 PM

I think it is your best mod yet. :D

:guitar:

fustercluck

12-08-2007, 05:52 PM

It IS attractive isn't it? :hillbill:

So I had a few sort of stumbling blocks to transcend; some of which I'll detail here. As I have lamented, months of neglect toasted my battery. I tried to recharge it, but the poor thing was DOA. Fortunately, it was an Interstate battery and they warranteed it for me even though it's early demise was my doing. I picked the new battery up and it has been sitting under the runner until today. I installed it, turned the key and...

...nothing. How deflating. I panicked and hung my head in self pitiful shame. Crestfallen, I went inside and began the honey-do list. After a few minutes of moving stuff around for the benefit of others, the lightbulb lit up. I had toggled the kill switch a few months ago when the runner was parked outside and ther was no way to secure it. I bounded down the hall and out the door to the garage. I flipped the switch, turned the key and...

...IT'S ALIVE! ALIVE!!!!!

http://www.donaldsensing.com/Pix/0503/its_alive-fstn.jpg

fustercluck

12-08-2007, 06:06 PM

Another obstacle was that after the lift was installed, the front driveshaft was too short. I took it to Tom Woods custom drivelines http://www.4xshaft.com/index.html and in one day they had the proper modifications completed and the shaft balanced.

Most folks only get to see the website and while it is attractive, the real magic hapens here...
http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails129.jpg

This able technician is balancing a newly reconditioned drive shaft

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails130.jpg

the camera doesn't show it, but this driveline is really spinning. The grease on the wall behind is from centrifugal force

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails131.jpg

these are ready to be shipped out

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails132.jpg

I caught them on clean-up friday

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails133.jpg

Hehe. Surprisingly, none of the techs were interested in being exposed on the web so no face pics :D

callmej75

12-08-2007, 06:08 PM

Belay my last....

CARRY ON

fustercluck

12-08-2007, 06:17 PM

So I impatiently bolted the shaft on and began working on another obstacle...

Anyone notice what is amiss with this fender? Hint: this is the passenger fender and the blue tape indicates my intent...

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails134.jpg

...anyone? Anyone?????

...there is no ANTENNA FREAKING HOLE!!!!!!!!!!!!!!! This is a replacement fender and it came with no antenna hole; presumably this fender was meant for the European market or any of the other places whose people drive on the wrong side of the street. Regardless, I had to cut my own while not damaging the work I had here-to-fore completed. The blue tape was to indicated a baseline for the template I made to mark the position of the hole.

fustercluck

12-08-2007, 06:31 PM

This pics shows the template I made from another sacrificial fender and the spot I sprayed onto my fender with gray primer. This way I could at once mark the perimeter of the hole and it's position/orientation. While the primer dried, I went in for some homemade chili (where's the 'yum yum' emoticon?)

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails135.jpg

It's not easy to see here, but I have perforated the perimeter with a series of tiny drill holes. To prevent the bit from wandering as if it were some infamous Democrat President from Ark., I used the spring-loaded nailset seen on the hood in the background to mark and start the holes.

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails136.jpg

I used a Dremel to cut and grind the metal into shape. The black goo is POR15 that I applied to the bare metal inside and out. It will be covered by the rubber grommet that rests at the base of the antenna.

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails137.jpg

when this dries, I'll mount the new antenna.

fustercluck

12-08-2007, 06:39 PM

Nothing like brand new weatherstrip to top off a project...

http://i40.photobucket.com/albums/e201/1fustercluck/85runnerdetails128.jpg

This is the in and out weatherstrip that goes on the tailgate at the top where the glass rides.

After these were installed the dry-in stage was finally complete.

I also had to replace a cable for the rear latch release mechanism. The old one was bound up and wouldn't be of service. I would have snapped a pic, but hey, it's just a cable man...:hillbill:

EWAYota

12-08-2007, 06:39 PM

your sticker looks crooked :tongueout:

callmej75

12-08-2007, 06:43 PM

your sticker looks crooked :tongueout:

I didn't wanna bust his bubble so I let you have the honors.... :smokin:

fustercluck

12-08-2007, 06:43 PM

So, all that is left to make this truck road worthy, is to jack up the front and double check the steering lock to lock, torque the lug nuts and bolt the seats in. I'll do all of that tomorrow...pics imminent.

fustercluck

12-08-2007, 06:47 PM

your sticker looks crooked :tongueout:

Hehe. It does, relative to the old bent weatherstrip, but to the defrost lines, it is parallel and horizontal/level. I took it back off anyway, because I may not use that glass after all.

fustercluck

12-08-2007, 06:49 PM

your sticker looks crooked :tongueout:

I didn't wanna bust his bubble so I let you have the honors.... :smokin:

Since when did you change this policy? :tongueout: :flipoff:

callmej75

12-08-2007, 06:51 PM

haha...(pats fuster on the back) good job man..way to overcome! :hillbill:

fustercluck

12-08-2007, 07:18 PM

Hey J, my machinist friend and I will begin mocking up the new bumpers on the 15th of this month. I'll start with cardboard representations of the parts and their fitment and finish with steel. Really, this is the part I have been impatiently anticipating for months...be prepared for a shipment of parts to PC, my friend!

callmej75

12-08-2007, 07:23 PM

Alrighty man...2 bumpers and sliders...right? This way I know how many lbs. of the color we discussed before and clear coat I will need. It will be undoubtedly look great! I need to get with Chris as well for a vinyl graphic of the logo..

fustercluck

12-08-2007, 09:58 PM

Yep, sliders too. Then I can lose the nerf bars so Wab doesn't tease me anymore :hillbill:

SLC97SR5

12-21-2007, 02:11 AM

Wow, I just read the whole fetchin' (welcome back to Utah) thread. That's some amazing work. That's cool you may pick up that 1st gen, I tried calling him but didn't get a response, this was over a year ago. I did however score on a '84 flatbed.

fustercluck

12-21-2007, 07:30 AM

Hehe. I've been too lazy lately to finish the last three things for road worthiness. Should finish on Christmas day....

:D

04 Rocko Taco

12-21-2007, 07:38 AM

I need to get with Chris as well for a vinyl graphic of the logo..

Im here whenever my man!!

waskillywabbit

12-21-2007, 02:28 PM

Yep, sliders too. Then I can lose the nerf bars so Wab doesn't tease me anymore :hillbill:

Yes, please do!!! :flipoff:

:guitar:

fustercluck

12-23-2007, 09:44 PM

I have been saving a series of pics to document the disassembly and reassembly of the tailgate from complete unit to empty shell. Sadly, I have lost the digi-card that contained those images. Due to the complexity of that assembly, I just don't feel like doing it all over again just to harvest new pics for visual aid. The following is an attempt to vividly describe step by tedious step the process for removal of the components in order. Replacement, of course, will be done in the reverse.

The tailgate as a unit is, as I said before, a complex amalgamation of electrical and mechnical parts designed to function within the confines of safety and protecting the glass from being raised under any condition but by the intended design; only when the gate is closed and with the shell on.

As one approaches the tailgate, the first step is to lower the glass into the gate shell with either the key or the toggle on the console. At that point, the gate can be manually unlocked and opened in the usual manner. Now the disassembly can begin.

Remove all of the fasteners that retain the interior panel in place and set it aside. I always put fastener groups in a zip lock plastic bag and label it with a sharpy marker. (Since this will be a long article, I'll post it in sections so as not to accidently lose them...here goes) Con't.

fustercluck

12-23-2007, 10:00 PM

This should have exposed an isosceles trapezoid shaped sheet metal protective panel fastened by four screws. Remove and place the screw in a container. The panel should come free at this point.

Now one should see the motor and regulator assembly anchored by 4 bolts with a ground tether at the upper left bolt. There are two cables radiating out toward the latches on either side (right and left). These cables have retainers which snap into holes stamped into the gate shell. With a screw driver, gently press the retainer barbs together and the retainer will drop free. Do this to both sides if you intend to remove the motor assembly and separate it from the window.

At the now lower edge of the gate (closest to you) there is still a plastic trim panel fastened with ten screws (maybe eight….could be nine screws) and bound to the gate shell by the release handle and lock knob. Con't.

fustercluck

12-23-2007, 10:16 PM

To remove the plastic trim, one must first extract the release handle and lock knob. Here’s the bummer part…….On some early runners, the retainer clips that tie the release handle and lock knob rods to the motor assembly will not allow the rods to be freed without breaking the clips. These clips can still be had at the dealer for about .50 cents each so go ahead and break them. Place order for new ones in a little bit….there will be a bit more breakage ahead. Free the rods from the motor assembly and remove the two screws that bind the release handle to the gate body. The lock knob will pull straight out while the pull handle will need to be slipped forward about and inch to escape a ledge and then wriggled out to escape the confines of the motor assembly and gate shell.

Your plastic trim should fall free now. If the purpose is to remove the glass also, then the inner window felt will need to come out. If you are super heroically patient, you can reach into the shell and free the ten or so impossibly brittle plastic clips that hold the window felt in place. When you resign yourself to reality, break them from the inside, and put them on the ‘to be ordered’ list. Remove the window felt. If it is not bent or deteriorated, save it for reassembly. If it is equally worthless as the clips, the felt can be ordered from the dealer with clips as a unit for around 30.00.

fustercluck

12-23-2007, 10:32 PM

Now we can separate the glass from the motor assembly regulator arms. The arms in the ‘down’ position are at the ‘bottom’ of the door shell (now the top from your position). Remove the four retaining bolts we discussed earlier. The motor assembly should move side to side without being limited by the hinge cable retaining clips. Unlike the driver and passenger door window assemblies, the regulator arms do not have the ‘C’ channel attached to them and there are no bolts that fasten the regulator assembly to the glass slab. The ‘C’ channels in which the regulator arm wheels ride as they lift, are part of the glass frame and there are two channels about 8 to 10 inches apart . To separate the arms from the channel, slide the motor assembly to one side far enough so that the little nylon wheel slips free from it’s chase. Then, slide the motor to the opposite side until the other wheel slips free. The glass is now separated from the motor and will ride in it’s rails independently of the regulator arms.

fustercluck

12-23-2007, 10:59 PM

Some runners are equipped with defrost. Slide the glass slab up until the plug is accessible and disconnect it. Remove the glass by manually sliding it up and out of it’s rails and out the top (edge closest to you). Now comes the hard part….

There are several harness retainers that must be removed to free the harness enough to allow the motor assembly to be extracted. Take heart, these retainers will inevitably break and can be replaced for under 1.00 each. Just break them and be done with it. There are three sizable screws that hold the latch mechanisms in place at the right and left of the gate body. Unscrew them and the latches will fall free. At this point, the motor assembly is completely independent of the gate shell. Reach into the bed side cavity (past the plastic interior panel) and unplug the gate harness from the main harness. Press the rubber grommet through which the gate harness passes, through the cavity. Push hard, it will pass through the body sure enough… That harness passes through the gate shell via a plastic directional cap which is fastened with two screws. Remove those screws and lift the cap away from the tailgate. Press the harness and grommet through the gate's sheet metal. Next, follow the harness toward the top of the tailgate (closest to you) and find the connection that energizes the key operated switch and license plate lights. Unplug that pigtail.

To this day I can’t recall the contortions both facial and manual that I employed to remove the motor and arms from the shell. Suffice it to say, you’ll scratch paint and shout expletives at the dog until suddenly the motor crank part will pop out such that the regulator arms only remain. The arms can be slipped out by moving the assembly to one extreme of the given opening and bending without distorting the arm enough to clear the rim of the shell. The other arm will be no trouble. The cables and latches will all come out now.

Access to the key switch and license plate light assembly fasteners is now possible. These can kinda be accessed without removing the glass and motor assemblies, but it sucks and you’ll be frustrated for extended periods of time. There are two nuts and a center push in fastener that I had to pry out by pressing the barbs away from the body panel hole.

fustercluck

12-23-2007, 11:10 PM

All that is left now is the counterweight spring and those rattley arms that keep the gate from opening too far….not to mention some knick knacks like rubber bumper disks and some little clips that most anyone can decipher how to remove just by examining them. To remove the counterweight rod, close the gate to release the tension and climb under the vehicle. At the bottom of the gate there is a rod that rides over a humped nylon piece located directly in the middle and at the very back edge of the runner bed. There are four bolts that fasten the counterweight rod to the gate shell. Remove those, and the rod will slide free. The gate limiter arms can be unscrewed with a large Phillips screwdriver or an impact driver if the screws are frozen in place.

Tomorrow or the next day, we’ll discuss the reverse procedure and what I did to improve function.

slosurfer

12-24-2007, 08:43 AM

Maybe your digi-card is in your newly reassembled tailgate. :flipoff: Do you know if the internals are just about the same in the tailgate from the first to second gen.? Obviously the actual window on gate are different, but what about the internals?

Is your wife going to just put a big bow on the 4runner for your christmas present? I bet she'll be glad when it is done.

Great job so far and excellent documentation on the whole thing. :thumbup:

amgraham

12-24-2007, 10:10 AM

Thanks for the write up man.. You know I can use it :hillbill: . I still haven't gotten around to pulling the gate apart.. I've been busy working on this little thing that I got the crazies and bought over Thanksgiving :P :

Before:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02406.jpg

Currently:
http://i63.photobucket.com/albums/h146/amgraham83/1987%20Suzuki%20Samurai/DSC02552.jpg

Build thread if curious: http://va4x4.com/forum/viewtopic.php?t=1348&start=0&postdays=0&postorder=asc&highlight=

Too bad you're so far away.. I could obviously use your mad body work skills :D

OK, hijack off. Merry Christmas!

fustercluck

01-01-2008, 05:44 PM

Hehe. I met one of those Sammies while wheeling out in the desert in Az two years ago. I was impressed at how capable they are. Previously, I had dismissed them as wannabe's. Looks like a good find!

I'll continue the tailgate assembly description in a couple of days. The holidays have been brutal with all the eating and sleeping and relaxing and lounging and recreating and eating, that I have procrastinated any constructive activity...well, most constructive activity.

I did manage to get the runner out of the garage and on the road today. I spent whicever time I had between the aforementioned holiday glee working on the last few items on the roadworthiness punchlist. I got the rear view mirror mod done and the windsheild washer nozzles in place. I touched up some bare metal on the frame with some extra POR15, checked all the fluids and torqued the lug bolts. I did a final once-over on every mechanical mod I had done and cleaned up my mess. When all this was done, I started her up and drove down the street. She seemed okay, so I took her to the gas station and filled the tank for the first time since April of '07 (and bought a diet DrPepper for my own tank...). On the way around the block, I shifted into 4wd and drove into a three foot snow bank. She climbed it as best as was possible since the snow was not packed hard enough to support her weight.

I have some pics, but Photobucket is REALLY slow right now. I can't even upload the new shots I took today...

fustercluck

01-01-2008, 05:47 PM

Okay, they must have been busy over at Photobucket...
Her name was madeleine back before I started all of this, but now that name kinda doesn't fit. So, may I introduce Darth Fuster!

http://i40.photobucket.com/albums/e201/1fustercluck/darthfuster002.jpg

http://i40.photobucket.com/albums/e201/1fustercluck/darthfuster003.jpg

slosurfer

01-01-2008, 07:58 PM

Oh man! That is nice! :clap:

jrallan26

01-01-2008, 08:01 PM

Fuster,

Looks great! As for the holidays I can totally relate! I havent lifted a finger since Christmas eve. Tonight is my first night back at work since xmas eve, its going to be a rough night....

04 Rocko Taco

01-01-2008, 09:44 PM

Looking great buddy. Can't wait to see it in person....

just wait.

plans are forming ...

fustercluck

01-01-2008, 11:23 PM

Looking great buddy. Can't wait to see it in person....

just wait.

plans are forming ...

*salivates*

waskillywabbit

01-02-2008, 07:21 PM

You should call it "Darth Fuster with :gay: nerf bars" :flipoff:

:guitar:

fustercluck

01-02-2008, 07:41 PM

You should call it "Darth Fuster with :gay: nerf bars" :flipoff:

:guitar:

:lol: :lol: :lol:

jrallan26

01-02-2008, 07:46 PM

ouch!

fustercluck

01-02-2008, 07:46 PM

So I drove it around today listening for noises and sniffing for tell tale smells. I was having a blast enjoying the fruits of my labors (and those of my friend Ryan who helped a TON.). I noticed that the steering is a bit stiffer than it was with the J arm push/pull configuration. Is that typical? Also I think I'm getting a bit of the 'death wobble' motion when I hit a bump in the road. I thought the steering stabilizer was designed to dampen that. Anyone have experience with this?

jrallan26

01-02-2008, 07:49 PM

tire pressures too high?

fustercluck

01-02-2008, 07:54 PM

Hmmm. that's a possibilty. I'll give it a look...

waskillywabbit

01-02-2008, 08:07 PM

Yes, IFS box steering is stiffer IMO to the J-arm push/pull system.

What exactly all have you done to it with the new steering? Aligned it yet?

Yours sounds like "bump steer" instead of the typical "death wobble" which is associated with vibrations at certain speeds that about vibrate your fillings out. Both are associated with suspension geometry and/or steering geometry.

:guitar:

fustercluck

01-02-2008, 08:21 PM

All four tires are at 40 psi. They are TA KO's

fustercluck

01-02-2008, 08:24 PM

I haven't aligned it yet. I'll probably do that asap. I've mostly been test driving it and crashing through snowdrifts (:hillbill:). Bump steer is exactly what it feels like. The steering wheel jerks right to left when I hit a bump at higher than 25 mph...

fustercluck

06-03-2008, 09:35 PM

Well as y'all may have guessed, I haven't done much on the runner all Winter/Spring. Mrs Fuster and I have been living in limbo while we established ourselves here in Ut. After exhaustive research and waiting out the softening realestate market, we've finally chosen a modest home to buy. The best part is that it comes with a 2 1/2 bay shop with 12-15 ft. ceiling clearance. I am beside myself with anticipation of finishing the runner and continuing the second phase of this build....'course, being a 'new-to-us' home, there will doubtlessly be a daunting list of honey-do's that will be expected of me before I can play with my toys...

Anyway, here's a pic of the shop. It's kinda homely, but it's heated and cooled with a smooth finished concrete floor and drainage. It has hot/cold running water and is energized with 220 power. I have always wanted my own shop.

http://i40.photobucket.com/albums/e201/1fustercluck/shop-1.jpg

Sorry, the pic is small. I'm going back there on Saturday for a final inspection. If I remember the digicam, I'll get some larger pics inside and out. Wish I had this while I was painting the runner...I wouldn't have so much trash in the clear-coat.