4runner+Flippac

[thebrassnuckles]

I just picked up a Flippac, and I plan on shoehorning it onto my 1st gen 4runner.:wings:

I'll get pics tomorrow..

The Flippac is an older one off a import longbed.. it is the correct width, I just need to cut about 8" off the front and fabricate a passthrough to get a good seal on the back of the cab where the factory top seals...

I dont think it'll be too hard...

seeing as I have never done anything like this and I have never fiberglassed before...:Wow1:

so... thats the plan...

comments?

questions?

[Overland Hadley]

Sounds like a good project.

:lurk:

[thebrassnuckles]

How does one remove the top folding portion of the flippac? I want to remove it so it is lighter so I can move it around easier and stand up inside while I'm reshaping the front portion.

[elcoyote]

How does one remove the top folding portion of the flippac? I want to remove it so it is lighter so I can move it around easier and stand up inside while I'm reshaping the front portion.

You will need to unload the torsion bar, that is done by positioning the top (bed) vertical, i.e halfway though its travel. The following instruction about replacing the torsion bar will shed some light on what to do. It's not easy and you'll need some help. A gantry or a block & tackle on a beam would be helpful

http://expeditionportal.com/forum/showpost.php?p=433287&postcount=5

[austintaco]

You will be my hero when you finish this project. I am sure I am not the only 1st gen owner that has wanted to do this.

[thebrassnuckles]

You will be my hero when you finish this project. I am sure I am not the only 1st gen owner that has wanted to do this.

I read one too many thread asking if it was possible. I decided. It's time to find out. I'm a both feet kinda guy. I'm pretty handy. Sometimes my work comes out looking good. Sometimes it's functional at best. But I am gonna try to make this one look good.

I saw the flippac for sale and I couldn't resist.

I do not have a torsion bar. At all. I already called at and whoever it is that makes the flippac. They won't have any in stock for a month and they are $285.

[thebrassnuckles]

OK, so I am trying to decide on the proper construction techique for restructuring the front part of the camper..

does anyone know how the flippac is built? like is it a plywood structure that is flassed on both sides? or is it a single layer of fiberglass or is it fiberglass over a foam core?

I am trying to work out a plan for building the pass through, and I need to know what material to build it out of
any help would be great.

Thanks
Bill

[thebrassnuckles]

here is the flippac and the cuts i am needing to make, i need to move the front wall back 8"

[SilverBullet]

Almost looks like a short bed FP would be perfect for you. Might want to look at the design of those for inspiration, since you ended up with a long bed version.

[thebrassnuckles]

Almost looks like a short bed FP would be perfect for you. Might want to look at the design of those for inspiration, since you ended up with a long bed version.

yea, the 4runner is supposed to be identical dimensions to the sb 2nd gen pickup, but with the way the camper shell attaches to the back of the cab, I think it may need to be a few inches longer.

I am thinkin about just making the cap seal out of some thinner ply wood bent around the edge real well and then take another shee of plywood and cut it to fit the shape of the cap seal..

lets see if i can paint shop a pic i have of my runner...

[thebrassnuckles]

heres an extremely ghetto paint of what i'm gonna try..

[billy bee]

here is the flippac and the cuts i am needing to make, i need to move the front wall back 8"

I don't know about the construction. But it does appear that you are removing a section of the FP critical to its overall structure. I know you will be replacing that front bulkhead section with a 4Runner cab, but be careful handling the unit once you make those cuts. I have a FP manufactured in 2003. It is far from overbuilt. Your earlier unit may be stronger, but I think the sides would be compromised if subjected to any lateral racking motion at all. It'll be easier to do if you remove the flip lid and tent components. Should be easy as the torsion rod is gone.

If you have not looked it over already, look at Bella's build thread. He was dealing with the back end of the unit rather than the bulkhead/front end. Still may give you some insight.

Good luck. Looks like fun.

bb

[thebrassnuckles]

I agree with you 100%

I need to figure out a way to remove the top portion of the shell to relieve some weight, I havent had a chance to open up the top at my house yet, with the lack of torsion bar its real heavy, i need to build a better stand than its on right now, lower and with wheels. then I should bve able to get the leverage I need to open it up.

I night tr building an x pattern temporary crossbenber inside the shell and bolt it to the bedrails and clamp it to the top opening or the windows to prevent anything from getting out of alignment also..

I think I will also lay down a couple extra laters of fiberglass on the inside of the srtucture to make up for the loss of strength, and I am going to build the new front part of the shell from 3/4 plywood so it should be pretty strong....
I hope..

I need to find a place locally that sells the bendable plywood for the cab seal, or I could try to bend some heavier marine grade plywood with steam and bolt it to the top and let it dry out and hopefully retain the desired shape.

I would prefer to do the latter and I thing I could get a better attachment to the front valance of the top when the time comes.

[thebrassnuckles]

another thought I had, after reviewing several other folks build threads would be to leave the length as is and modify the current front valane to fit the 4runner, and just build an extension box that makes the rear ensclosed, but that would probably come out looking like crap..

[thebrassnuckles]

talked to my buddy, he used to race sailboats when he was in his teens, he said he has lots of experience with fiberglass and that he'd love to help me out with that part of the build. :wings:

sweet!

[austintaco]

Is the FP longer than the bed of the truck or is it the other way around?

[thebrassnuckles]

Is the FP longer than the bed of the truck or is it the other way around?

The FP is longer.
I pulled the topper off last night and I found that the leading edge of the 4Runner is a curve, so it slightly complicates the plan. but not much.

[BIGdaddy]

The FP is longer.
I pulled the topper off last night and I found that the leading edge of the 4Runner is a curve, so it slightly complicates the plan. but not much.



Keep it up, brother!!!!!:wings::wings:

This is a great idea, using a great platform. Take your time, and I think you'll be VERY stoked at the results.

Cheers,
Brian

[thebrassnuckles]

I hope so, when I was pulling the factory topper off last night, I uh, did it by myself...

yeah, it fell of the side of the bed and came slamming down on the rear corner of the bed and cracked the factory top...

oops...:Wow1:

but the top already had a bunch of cracks in it on the back where the window slides in.. but its not too bad.. besides, I dont think I would have ever wanted to put it back on once I get the flippac installed, cause who in their right mind wants to pull off a heavy top to put another heavy topback on.. guess its just motivation to make a soft top too..:smiley_drive:

payday is this week so maybe this weekend after I get back from fresno I can do a bit of work.

I also found that the inside rails of the 4runner are 53-1/4"

and the inside of the lip on the rails of the flippac are 53-1/2" so I'll probably have to redo those too.. I was planning on reinforcing them anyways, I'll just cut off the lip that is on there and reform it more narrow. aint no thang:ylsmoke:

[thebrassnuckles]

So I'm standing in my garage lookin at my 4runner, and the top I took off it and I thought, How reasonable would it be to take the factory top and slice and dice the whole rail mounting interface off it, and graft it onto the flippac? it would save me having to fab up some kind of seal, as its already made, my top is broken..(not really all that bad, but if i get the flippac done I wont be wanting to switch between tops, it'd be either on or offf.)

I'll have to call my local fiberglass expert..;)

[Toyotero]

So I'm standing in my garage lookin at my 4runner, and the top I took off it and I thought, How reasonable would it be to take the factory top and slice and dice the whole rail mounting interface off it, and graft it onto the flippac? it would save me having to fab up some kind of seal, as its already made, my top is broken..(not really all that bad, but if i get the flippac done I wont be wanting to switch between tops, it'd be either on or offf.)

I'll have to call my local fiberglass expert..;)

I was about to make that same suggestion... totally do-able... it'll be a lot of work but less than making it from scratch and probably with better results.

Take lots of photos, this could turn into an epic build :-)

[thebrassnuckles]

I had a reply all typed out lastnight, but the malware warning shut that down....

so, lets try again,

I have thought of 3 options:

1. build a plywood interface structure, and glass overthat and attache it to the flippac

2. chop the topper, and graft it to the flippac

3. Mask off and glass the bed trails and graft that to the flippac, essentioally the same as #2 but minus the destruction of the factory topper just in case.


I think 3 will end up being the cleanest, ad least amount of work, plus if everything goes to hell I can still put the factory top on there..

[Ruined Adventures]

This thread really got me wishing Flip-Pac had an option that fit a 1st gen 4runner so I sent an email a while back to inquire...Totally forgot about it, then this showed up in my inbox today:

"Hi, my name is Diane. im the flip-pac sales representative. I'd be glad to help you if you give me a call at 1-800-327-5836 m-f 9-5 . these are our current prices for Flip-Pacs. if any customizing is necessary (ex. non standard truck bed) , then there will be additional charges.

All mini-bed trucks (<6' box-size) - $3850.00 + tax
All short-beds ( 6'6" box) - $3950.00 + tax
All long-beds (8' box) - $4250.00 + tax"

You'd be looking at $4k+ for a custom FlipPac that fit a 1G 4runner. I can't justify that price...maybe at another point in life. Just figured I'd pass this on to the others who'd be interested. Now we know they'll at least entertain the idea. :victory:

thebrassknuckles, how's the DIY version going?

[thebrassnuckles]

I thought I had replied to this.. oh well..

As of right now, I have doen.... nothing..

I am waiting on a torsion bar from FRP, they said itd be another 4 weeks...:Wow1:

I have found out how to remove the flip portion of the shell, have sourced my glassing materials.

I have been reading up on fiberglass repair and construction.

I have been developing a plan for the cab to shell interface.
I may be taking a job across the country so.. I either need to crank this baby out or drop it for now.. the job starts in mid December..

I am leaning towards the former..

[expedition4x4]

might be an easier undertaking to extend the bed of the 4runner

[thebrassnuckles]

might be an easier undertaking to extend the bed of the 4runner

I have thought of this, but I would still need to fabricate the cab to shell junction..

that and extending the bed an additional 8" would greatly increase my departure angle, uless I extended before the rear wheel, and stretched the wheelbase, but that would be a huge undertaking, costing millions of dollars and thousands of lives.

and it would increase my already gigantic (coming from a former tj driver) turning radius.

I think that modifying the FP would be the best balance between ease, cost and offroad performance.

even easier would be to slap the dang thing on a trailer and call it done....

but that wouldnt be as sweet...

[tanglefoot]

I was planning on putting a Wildernest (another tent-shell but it folds out to the side) on the 4runner for a while. I was just going to trim the front wall out of the shell leaving a bit of seam for strength, slide it onto the 4runner and seal the gap with foam. I have had a regular pick-up shell on the 4runner before and did the same thing. It wasn't professional looking, but perfectly functional.

I went a different crazy route instead and put a pop-up camper in it. It's pushed up to the back of the cab as close as it will go and then sealed with expanding foam. Again, not pretty, but functional.

Here it is with an aluminum truck shell on it and regular pick-up shell clamps to hold it on. I just cut small rectangular holes in the bedside interior paneling for the clamps. When 4-wheeling around Telluride, I slid the shell back a few feet and tightened the clamps so my passengers had an open-air view. As soon as the storm clouds started threatening, I'd slide the shell forward again and seal things up. The front edge of the shell had a length of copper pipe foam insulation over it that compressed between the shell and back of the cab for a nice seal.

http://i786.photobucket.com/albums/yy142/Tanglefoot80/mine2.jpg

Here it is with the current camper (and different paint). This time I'm using expanding foam (Great Stuff) between the camper and cab.

http://i786.photobucket.com/albums/yy142/Tanglefoot80/6-4-10%20Haul%20Road%20Camping/P1010807.jpg

With a 1st gen 'runner, the possibilities are endless! Good luck with the project!

Eric

[thebrassnuckles]

I'VE DONE IT!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!:wings:


Finally formulated a plan for creating the cab to FP junction that is..


after many terrible sketch drawings on my little notepad here at work, I have developed a plan that I feel will be the best compromise between time, cost, and function.

I am going to cut the FP to the required length, attach a cardboar template to the outside of the FP and 4runner, cover everything I dont want stuck with tape or some other non-permeable covering, and get inside and start glassing.

to start will be a layer of chopped mat, resin, a cloth tape, resin, mat, resin and then possibly this real heavy cloth that the boat shop has, resin and some more mat, until I feel like its had enough, then I'll remove the cardboard from the outside, see what kind of finish is on the exterior, and grind down the seam on the outside a bit, and put some more resin and mat on the seam of new/old glass on the outside, and then sand, and prime and paint...


I think that will work.

so the structure will be all fiberglass, I will be using the actual mounting surfaces of the 4runner as the mold, so there should be minimal fitment issues. Hopefully the cardboard will give a pretty good finish on the outside so I wont have to do too much sanding to get a smooth finish, and the seam will be reinforced from both sides for the most strength.

any fiberglass gurus know if my plan will fail miserably?



if there are no issures with the plan, all I need to do is find a couple of strong friends to help me move the FP, and remove the top part. and get to it.:bike_rider:

so I'm hoping next weekend I'll be starting.. (unless the wife has something she really needs done..)

[Ursa Minor]

cut the FP to the required length, attach a cardboard template to the outside of the FP and 4runner, cover everything I dont want stuck with tape or some other non-permeable covering...

...start will be a layer of chopped mat, resin, a cloth tape, resin, mat, resin and then possibly this real heavy cloth that the boat shop has, resin and some more mat, until I feel like its had enough, then I'll remove the cardboard from the outside, see what kind of finish is on the exterior...

...Hopefully the cardboard will give a pretty good finish on the outside so I wont have to do too much sanding to get a smooth finish, and the seam will be reinforced from both sides for the most strength.

Ok, here are some old fiberglass tricks that may save some time on your fabrication -

You can use cardboard as a template on the outside, but it's going to absorb the resin and soften and will be a mess to sand off.

You might try some 1/8" door skin from Home Depot or similar. Get some spray adhesive, like 3M 77, while you're still at Home Depot. Once you've got your template cut to size, spray it with the 77 glue and cover it with aluminum foil. You can also glue foil to cardboard. Apply the foil as smooth as you can get it since that's going to be surface you get on your part. When it's smooth, get a solid layer of automotive wax on it, leave the wax "cloudy", don't wipe it off (like you would on your car) That wax will keep your resin from sticking to the template. You can also wax up your 4runner anywhere you might get resin for the same reason.

Before mixing up a big pot of resin, I do a test run on a 1' x 1' sheet of scrap template - ie, foil, wax, then lay up the part like you think you want it - all the layers etc. that way you know how long you have before the resin cures, and how thick it'll come out. Do this in the same orientation as your part will be, so if you're laying up a wall, have the plate vertical clamped in your vise maybe. You'll see if you need to thicken the resin so it won't run off too fast.

For an odd job like this where I don't know how much resin I need, I set up several 1 quart buckets/cups with resin in them but NOT catalized. Then as you get into the lamination, when you run out of one cup dump the catalyst in the next cup and mix and keep going. If you mix up a gallon or two in a big bucket, it's going to cure faster and if you get stuck somewhere you're going waste whatever is left..and I am always messier when I am rushing to finish before the pot goes off.

Thin cloths are easier on vertical walls as they wet faster and won't leave big voids. if you get a couple layers on, you can pull the FlipPac off and do the rest off the truck with it upside down which might be more pleasant working conditions.

Try to rough cut all your cloth to the size or in small sections before starting, it's so much easier to cut dry than covered with resin. Chop is better for corners, but several light layers are going to be easier than one heavy one to do any contours.

Good luck - I knew a guy with a wildernest who mounted it to his 4runner pretty much like you're doing.

cheers, John

[allochris]

3 pages & no pictures? :coffee:

[weezerbot]

If only Ursa Minor would expand building their ECampers on other platforms (like a 3rd Gen 4Runner...*hint*) all of our problems would be solved! :victory:

I REALLY like the Elements, but they just can't go where my 4Runner can.

[Ursa Minor]

but can your 4Runner go where my Rubicon Unlimited can? :smiley_drive:

[weezerbot]

Very likely, in comfort and without fear of breaking down!

Oh! :violent-smiley-031:



:sombrero:

[CYi5]

Very likely, in comfort and without fear of breaking down! Oh! :violent-smiley-031:


Zing!

[thebrassnuckles]

Pics you say...

I just went out aand pulled the top off my flippac and snapped a few pics....just for you

To remove the top portion of the fp one must first remove the tent and Tbar.. I have no Tbar so I will omit that step.

Next you will need to gain access to the screws on each corner.

To do this lift the rubber on each corner, mine was loose b ut some may need to use a razor blade

Next you find the little tubes holdinh the tent in place.. I grabbed them with needle nosed pliers. Then just pull that sucker out. There are 2 sides one front and one rear. I did not remove the tent from the upper half.

http://i27.photobucket.com/albums/c199/brassnuckles/IMG_20101101_180409.jpg

You will then need to pull the corners of the tent off the weather stripping. Here is a picture.

http://i27.photobucket.com/albums/c199/brassnuckles/IMG_20101101_180509.jpg

The next thing I didwas remove the screw holding the tent bows to the lower half. I didn't get a picture of the next steps cause the lights went out.

I took some straps and strategically placed them to keep the tent from opening.

I then called my 110 pound wife to help lift this monstrosity off.

She laughed.

I then shimmied this beast (with her help) to the floor.


Next I realized (she told me) there was nowhere to put this thing.

So I grabbed my trusty half a skateboard dolly and wheeled it into a corner of my garage.

That's all for now.

Illget more pics tomorrow after work.

[thebrassnuckles]

Incase anyone is wondering what's taking so long... I have this little monster crawling all over the place.

Expo. Meet Sophie.

http://i27.photobucket.com/albums/c199/brassnuckles/IMG_20101101_200355.jpg

[walking eagle]

Funny, after my LX450 Burnt up, I was looking into a 1st gen 4 runner, and was thinking about how to put a flippac on one.

I think you have the right idea, but I'd modify it a little bit. Cut the 4 runner top to leave all the matting surfaces like you said. Then as you planned, cut the flippac to match as close as you can. At this point, I'd take some 1/8" x 3" aluminum plate. Attach it to the 4-runner toper. I'd probably drill through the topper and bolt it. Then do the same on the flippac. Now the two pieces are firmly attached to one another. Glass over the aluminum spars everywhere except where the bolts are. Now, you can take the bolts out and you're two pieces are still together. If the flip-pac is too long, just cut it so it goes over the cab. You can foam and glass it to match up (see link below on foam and fiberglass)

At this point, you just need to fill the gap. If it's a nice flat gap you can put some aluminum foil over boards or something, on the inside and glass from the outside, then remove the boards. If it's not nice and even and flat (more likely), get some foam from lowes or home depot - the house insulation foam ( http://www.rqriley.com/frp-foam.htm ) and attach it to the two toppers. Either glue it. or tape it securely - glue would be my 1st choice, double side tape second, just taping the edges would be my last choice.

The foam is flexable and will give a nice contour betwen the two toppers. Glass it from the outside - make sure you've sanded back far enough on both of them that you can get some overlap for strength. The aluminum spars will help with the strength though. You can now either glass over the foam on the inside (pick a thin foam - it comes from like 1/4" up to 3") or you can grab a scraper and pull the foam off, it'll be a bit of a mess, but not too bad. Then glass the inside after you have all the foam off. Paint the interior with bedliner and you're golden. :) You don't have to do the bedliner, but if you do you have to do next to no prep work compared to trying to sand all the fiberglassing you just did to a paintable smoothness.

My ultimate idea for a 4 runner was to do what you're doing, then make a trailer out of a 4 runner bed as well. Cut it just in front of where the toper mates. Why? Well, the acid fueled idea was I could put the topper on the 4 runner, and have a canvas toneau for the trailer. Drive out to Moab in a nice quite hard topped 4 runner, while pulling a low profile trailer. Then, once in moab, throw the bikini top on the 4 runner, and put the topper on the trailer and have a nice base camp. So, for some trips you could just have the 4 runner /camper, other trips, you could have the 4 runner plus a camper trailer. Just a rambling dream....

[walking eagle]

maybe this will help with what I'm saying...

1st is the 4 runner toper w/ everything cut off 4" back from where it mates to the truck. Aluminum slats are put on the sides and the front.

Then the flip pack - cut so that the height works out for the part that hangs over the cab, and the length works out so it lines up in the back - goes on, also gets attached to the slats.

Then you put a layer of foam and fiberglass to finish the bottom of the over cab section. And finally fiberglass in the gap between the two pieces.

[slus]

I'll be watching this one. Maybe I will take a few hundred hours off after grad school and do the same:sombrero:

[thebrassnuckles]

maybe this will help with what I'm saying...

1st is the 4 runner toper w/ everything cut off 4" back from where it mates to the truck. Aluminum slats are put on the sides and the front.

Then the flip pack - cut so that the height works out for the part that hangs over the cab, and the length works out so it lines up in the back - goes on, also gets attached to the slats.

Then you put a layer of foam and fiberglass to finish the bottom of the over cab section. And finally fiberglass in the gap between the two pieces.

I had entertained this idea before, but once I got home and looked at both toppers, I decided it would be alot more involved than just setting the FP on the skeleton of the stock top. The FP is a considerable amount wider than the stock top, so the walls wouldnt line up properly.

I got some more work done on my 4runner, but it was unrelated to the FP...

I got a new windshield, and am fixing my turn signals... the wiring on this thing is ridiculous.:Wow1:


this weekend I will be tearing out a bathroom and working on the backyard, if I get some time I may be able to do some work on the 'runner.

I will not be leaving in december so I will have more time to work on it.

There are still some mechanical issues with my 4runer I need to get worked out.. and I'm on a tight budget.

I did just save myself $150 though.. I lost my keys in the oil fields last week and finally found them... after massive amounts of searching...:wings:

[walking eagle]

I had entertained this idea before, but once I got home and looked at both toppers, I decided it would be alot more involved than just setting the FP on the skeleton of the stock top. The FP is a considerable amount wider than the stock top, so the walls wouldnt line up properly.

I would argue that it is exactly why is is a good way of doing it. You bend the straps such that one is centered over the other. Then lay in the floam, and it makes a smooth transition form one to the other.

The other alternative would be to cut just the very top off the flip-pac. Cut just the very top flat part of the 4 runner top, and then foam and fiberglass to make it all smooth.

I obviously don't know how much wider and longer the flip-pac is, so I'm just guessing on my models. I'd just really try to keep the 4 runner topper part where it mounts and seals. The one advantage of course is the ability to go back to a stock top if you wanted, or, if something happened to this 4 runner you could swap it to a different one easily.

[wyocoyote]

Did you finish this project, very enticing. I'm toying with something like this for my 85 4runner baja surftripper. The only drawback for me is it'd be pretty darn tough to pull the top off, and that's a big part of the beauty to me. Shoot I have a dying eurovan weekender, maybe I could graft its poptop onto it. Iguess what I'd really like is something like you are building, but the roof chopped above the driver as well that was still light and removeable. Even better removeable and campable, so i can tool around in my truck w/o it.Being a lazy man, I of course wish it was available aftermarket, being a cheapskate, I wish I could find it used. Being resouceful I really like this thread! Being wishful, I wish say can-back or softopper would make me a canvas cabover camper "shell" but i still need to have racks that will accomodate longboards. I know in mexico they custom make very nice camper shells from corrugated aluminum ( i think its aluminum) you know like the cheaper american camper shells, kind of like cheap metal sheds. that might be the ticket. sure its uninsulated, and will probably be loud, but should be light. Some where in the north of Mexico, they probably arent dirt cheap. I bet they arent afraid to fabricate they look well made. Please dont get all 'merican on me it is a japanese truck after all.
Better save up for a earthroamer, hope i dont hit my head on those granite counters as a passenger or a unimog with a hot scandanavian mechanic companion.
Let me know if your bitchen project has culminated.

[thebrassnuckles]

well I made a minute amount of progress today.

the FP is on the 4runner!!!!:wings:

but its just strapped on. and nowhere near anything ready to be permanently mounted...
but its something:elkgrin:

[Ruined Adventures]

well Rome wasn't built in a day!

I was just wondering about your project the other day, glad to see you're keeping with it.

[walking eagle]

well Rome wasn't built in a day!


And the 4 runner flip-pac wasn't built in a year (well 1o months?) :)

I stumpled across this thread the other day - again - cause I've been contemplating switching from the 80 series to a 4-Runner and doing this and was searching for flippac 4 runner, or 4 runner camper - and can't find anyone who's done this.

Front the photo it definately looks like you'll have to make it overhang the cab a bit.

[walking eagle]

didn't mean for that to sound negative, I just really really really really want to see this done, if they can do it on a jeep, you can do it on your toy... Saw a westy top on a cherokee around here somewhere, and this has to be easier than that!

[thebrassnuckles]

not taken negatively. I take forever.

Waiting on a router I ordered so I can get all the curves for the mounting surface made.
The FP will need to be lifted up about 2 inches to clear the top of the cab. The inside lip of the FP is slightly wider than the inside edge of the 4runner bed. so I am going to lift it with 2x6's and use those to mount it up all nice, and then i'll glass over all the wood inside and out making a fiberglass/FP/wood sandwich..\\I have the front walls rough cut. a bit more sanding and fitting, and it'll be ready. once I get my router i'll cut the needed curves on the 2x6's stick those to the front wall, and i'll be ready to cut up the FP.

[thebrassnuckles]

so... progress has been made.:wings:

i am nearing the fiberglassing stage.:Wow1:

some pics..

so stoked its finally coming together.

I had to double stack the 2x6's on the sides to get enough clearance on the overhang.. I could have gone with a single, but I was gonna be running about a 1/2" of clearance above the cab, 2" gave me a warm and fuzzy.

next step is to trim everything to final size, bolt it all together, spray foam insulate any gaps (im not the best woodworker, and I tend to "make" things fit:sombrero:)

and finally some fiberglass:Wow1:

hopefully my work schedule stays like it is. (home before noon:wings:) I'll have this sucker finished in a hurry....

also would like to finish her up so i can start DD this beast again.. my big new pretty truck costs me 100 bucks in gas per week:eek:

hopefully i post more progress tomorrow.:coffeedrink:

[Toyotero]

That's lookin' good man!

[thebrassnuckles]

That's lookin' good man!

Thanks!

its been a ton of work, and it has been pretty warm here lately, but I'm trying to crank it out so I can get a test run in it soon.

[jrueppel]

Looks pretty sweet already. Nice work!

[suntinez]

Looking good! I didn't realize your donor FP had the barn doors, that is very cool.

Is that wood on the vertical front side towards the truck? I was thinking that would be a pass thru but maybe not.

Watching with interest, love what you've done so far :D

[TACODOC]

That is going to be SWEET! :Wow1:

[thebrassnuckles]

Looking good! I didn't realize your donor FP had the barn doors, that is very cool.

Is that wood on the vertical front side towards the truck? I was thinking that would be a pass thru but maybe not.

Watching with interest, love what you've done so far :D

it is wood... and it is a pass thru. i used 3/4" plywood to transition between the cab and the shell, and a 1/2" sheet to seal the gasket on the cab, so its 1.25" of plywood there heavy, but its gotta be strong enough to support any torsional forces on the shell, since I cut out the original structure.

i'll snap a pic of it when I go out and play with it in a few minutes.

[thebrassnuckles]

ok, I bolted everything together today.

its pretty solid. I took it on a little shakedown to make sure it didnt fall do pieces.

all is well. the FP performed admirably. very solid. a few creaks here and there, butI think they'll work their way out.:smiley_drive:

next step, beautification.

sanding trimming, filling, repeat.:Wow1:

[Accrete]

build is looking good! i luv the ol'4runners.
One note on the "few creaks here and there"...if your wife is anything like mine she will want to crawl back there while going down the road and ferret out any noise and find a way to quiet things down back there. It is the one thing i had to figure out when going from our TACO to the Van!

best wishes on the project and enjoy : )
Thom

[thebrassnuckles]

build is looking good! i luv the ol'4runners.
One note on the "few creaks here and there"...if your wife is anything like mine she will want to crawl back there while going down the road and ferret out any noise and find a way to quiet things down back there. It is the one thing i had to figure out when going from our TACO to the Van!

best wishes on the project and enjoy : )
Thom

The creaks may be due to there not being any weather stripping on the bed/topper right now. it may quiet down with a bulb seal in there.

[Accrete]

yea once i posted my tid bit i thought some of my intention would get lost in the translation :)

I liken the "Pass through" on the 4runner with the camper-build/stuff in the flip-pack with what goes on in the back of the Van and a typical pass-through camper... your significant other will hear every rattle from camp-pots to rubbing sleeping bags :) . . .Mind you this is coming from a happily married (for 28yrs) man/husband/father who has a wonderful gift of selective hearing. None of the creaks seem to bother me!

Cheers

[JasonRedwood]

Nice work! Any idea what the weight difference is?

[Ruined Adventures]

This is so awesome. So, how much do you want to sell it for?

[thebrassnuckles]

This is so awesome. So, how much do you want to sell it for?

Sell it? I had never even considered that..... hmmmm.....:sombrero:

maybe someday.

[walking eagle]

looking good!

[austintaco]

very nice! I am glad its coming together

[noblhelix4]

Anything new with the project ?!?!?!

[thebrassnuckles]

as a matter of fact.... not much actually. work has been insane, 100 hour weeks.. the checks are nice though.

also, the guy i'm working with used to do fiberglass for a living. I am going to do some trading for work, when hes done the 4Runner will be glassed and painted.

I went and got a muffler put on it finally.

[thebrassnuckles]

Well, I had some fiberglass done on the 4runner.

I had a nice trade set up, but I had a falling out with the guy doing the work, so I'll be picking it up this weekend to finish it myself.

Oh well. He was taking too damn long anyways. I dropped I off at his house the day after i got the muffler put on, and he didn't touch it until last weekend.

http://i27.photobucket.com/albums/c199/brassnuckles/Snapbucket/21E4E5A9.jpg

[Toyotero]

It's looking good.

If you've never done it before, working with fiberglass is pretty easy for patch work like this.

Cheers.

[austintaco]

You are almost there. Looking good!

[JasonRedwood]

Nice I was just thinking about your build the other day.
Tomorrow I start cutting on a flip-pac build myself.
This flip-pac was a long bed camper right?

[thebrassnuckles]

yeah it was for a long bed.

picked up the 4runner this evening, tomorrow the lid is going back on..... I need to clean up the garage, and its been blocking the shelf for the Christmas decorations for far too long. pland is for next sunday to get some glass done on this mug. hopefully I can start cranking this thing out. sick of waiting around for other people to dilly dally.

the pic i posted of the work he did, thats all he did, one layer of glass on one side.... I might have to sand it all off too, I saw a few bubbles, and it doesnt look like he even ground down into the parent fiberglass....

some professional huh.

whatever. want it done right, do it yourself. didnt cost me anything but time. I was hoping to take it out for its inaugural trip this weekend.. (i love camping on superbowl weekend. not a soul out in the woods it seems.)

[thebrassnuckles]

Nice I was just thinking about your build the other day.
Tomorrow I start cutting on a flip-pac build myself.
This flip-pac was a long bed camper right?


I just saw you were in LA, Im in bakersfield... do I hear a 4runner/flippac trip being planned? haha.

[JasonRedwood]

I just saw you were in LA, Im in bakersfield... do I hear a 4runner/flippac trip being planned? haha.

Actually most of my camping ends up east of there near Shirley Meadows! My family has property in kernville and up in the mountains there. Lets do it when we wrap up these projects.

[thebrassnuckles]

Actually most of my camping ends up east of there near Shirley Meadows! My family has property in kernville and up in the mountains there. Lets do it when we wrap up these projects.

Thats my default mountain trip. I was just up there last weekend to get the kids some fresh air. Did a little hike by the fire station right there, unal trail I think it is.


i proposed to my fiance in the parking lot of the slopes haha.... it was more romantic than it sounds. nd my uncle has a cabin up there. spent many a christmas there watching godzilla movies with my grandpa.

[JasonRedwood]

That awesome man. I proposed to my fiance at a nature preserve that seconds as a dog park. It was more romantic as it sounds as well. Ha.

The property i go to is straight through Davis camp ground. Old gold mine cabin there but its so ancient i let the varments alone that live inside and i set up camp for myself outside.

[thebrassnuckles]

That awesome man. I proposed to my fiance at a nature preserve that seconds as a dog park. It was more romantic as it sounds as well. Ha.

The property i go to is straight through Davis camp ground. Old gold mine cabin there but its so ancient i let the varments alone that live inside and i set up camp for myself outside.

I'll have to check it out next time i'm around there.

[JasonRedwood]

I'll have to check it out next time i'm around there.

Watch out for sink holes and my distant relatives.(we try and keep them at distance)The minors and my grandpa used the holes back in the day to dump metal and other debri into. They are old vertical mine shafts that on ocassion will swallow anything. The gate is usually locked unless someone has broken in but you can shimmy through the fence. Amazing views around the back side of the hill.

[Ruined Adventures]

I was hoping to take it out for its inaugural trip this weekend.. (i love camping on superbowl weekend. not a soul out in the woods it seems.)
Awesome idea, why didn't I think of that! I could care less who plays or what commercials will end up on Youtube eventually.

[thebrassnuckles]

Awesome idea, why didn't I think of that! I could care less who plays or what commercials will end up on Youtube eventually.

I usually get pretty irritated if I know who is playing in the superbowl before the monday after. haha.

i just heard on the metal sirius radio station who is in it. drat. next year...

[RHINO]

dont ruin it for me i still dont know who's playing.

[SilverBullet]

Off topic, but u started it. My superbly festivities include a party every year, and the food always wins. I care less about football than I do lowered trucks, but time with food and friends is always good.

[thebrassnuckles]

did a little toying with the.... toy... today.

not much real work, but I needed to get my garage cleaned out, and the lid portion of the flippac was in the way so.....

http://i27.photobucket.com/albums/c199/brassnuckles/IMG_0946.jpg

http://i27.photobucket.com/albums/c199/brassnuckles/IMG_0947.jpg

Man is there a lot of room in this thing now... I'm 6' this is seated in the back seat, my hand is flat on the roof of the flippac. (i know there will be less room than this, but even with the tent installed, there is tons more space.)
http://i27.photobucket.com/albums/c199/brassnuckles/IMG_0945.jpg

I also started to play with my doors. They are in pretty bad shape. I peeled off the damaged wood sheathing, and discovered the particle board reinforcement blocks were all ruined from water.
http://i27.photobucket.com/albums/c199/brassnuckles/IMG_0939.jpg

http://i27.photobucket.com/albums/c199/brassnuckles/IMG_0942.jpg



I didnt get a chance to make new ones, but Im going to work on it this next weekend. (slave driver says we have housework tomorrow:Wow1:)

I bought a new deadbolt for it,as the old one had no key. I fitted up the lower door frame, and formulated a plan for filling in the gaps around it.

i took it for a test drive with the top on... definitely can feel a difference in the weight distribution. but it makes the 4runner drive a little better with the added weight.

[JasonRedwood]

Rad. Looking good. Made some progress as well, i have a game plan. Keep you posted.

[JasonRedwood]

Started a new thread in the yota area
http://www.expeditionportal.com/forum/threads/73422-1st-Gen-4runner-Flip-pac?p=1042905#post1042905

[thebrassnuckles]

well, last night I finished a chapter in my lifes book... I sold my 1953 chevy. I have had that car since I was 14. it was the car I learned to drive in.

I needed to clear the clutter up, and the money will give the 4runner project a kick in the pants.

85173

[JasonRedwood]

well, last night I finished a chapter in my lifes book... I sold my 1953 chevy. I have had that car since I was 14. it was the car I learned to drive in.

I needed to clear the clutter up, and the money will give the 4runner project a kick in the pants.

85173

Wow big sacrifice Brass. 53s and 54s are some of my favorite old cars. What are the plans for the 4runner besides the flippac?

[thebrassnuckles]

I love the 53/54 Chevys. I had 2, but I sold the beater 54 a while back.

Bumpers, fridge, winch, the works. Ha ha.

I also need to rebuild the hubs so I bought a hub rebuild kit.
I need a filler neck for a fuel cell I got in a trade that's going to be fitted as an aux fuel tank. I have a fold down rear tire carrier from my old jeep that I'm gonna put on to make room for the fuel tank.
I ordered the trail gear bumpers and a winch today. Waiting for a sale on the fridge. I know not a necessity, but I am tired of soggy goods.

I'm toying with the idea of an OBA set up, but still undecided. I don't want to blow all the cash. Need to save Some for a trip to Belgium this summer.

I'll also need some type of toilet (the fiancé's comfort is paramount.)

[JasonRedwood]

Nice cant wait to see the additions.

FYI
I talked to Don at West Systems this morning.
I had sent him a link to my thread so he could get an idea of what I am trying to accomplish.
Don suggested using their G-Flex system in combination with their liquid version of the accompanying resin.(honey consistency)
Also he said using a Biaxial glass would be the best bet.
This combo would get a strong and still flexible finish.

[thebrassnuckles]

Thanks! I'll look them up tonight. Can you buy from them online, or do you need to go through a distributor?

[JasonRedwood]

Thanks! I'll look them up tonight. Can you buy from them online, or do you need to go through a distributor?

Not sure if you can buy online. I didnt notice any store links. The store Im going to order threw said they would order any 'system' that i wanted.

[JasonRedwood]

Hows the progress coming?
Hoping to get some work done on my rig this weekend...

[thebrassnuckles]

I got a good layer Of fiberglass down. I wanted to make sure nothing would move when I took the top of the 4runner for the final fiberglass session, so I ground into the topper around all the edges and put a couple layers of chopped mat fiberglass on, made sure to stuff it real good into the tight gaps between the board and the topper.

I removed the top today. Maybe I'll have some good weather this weekend and I can get a little bit more done.

The hardest part was grinding down into the fibers of the topper.

I ended up using a wire wheel on my angle grinder. It got in there with the quickness. And it leaves a nice rough texture, which to me just seems like it'd be something I want for good fiberglass sticking.

I also got the new bumpers on, I saw the weather was starting to rain, so I grabbed a rag soaked in WD40 and wiped them all down. I need to get some paint on them.

No pics.

[JasonRedwood]

Hey Brass-

Have you removed the interior carpet on the flip-pac or are you letting it be?
I have been contemplating replacing it all, but the sanding mess is deterring me.

I got new rear roof latches and other things for the flippy but man this can of worms can get as big as you want or let it right.

J

[thebrassnuckles]

Hey Brass-

Have you removed the interior carpet on the flip-pac or are you letting it be?
I have been contemplating replacing it all, but the sanding mess is deterring me.

I got new rear roof latches and other things for the flippy but man this can of worms can get as big as you want or let it right.

J

I have been ripping mine out. It was some nasty white almost shag carpet. Really fluffy and nasty. I bought a couple of grey carped rugs at lowes for 20 bucks a pop. I plan on spray adhesive and sticking it in there. That's all that it looked like under the original stuff.

I'm gonna have to sand anyways to glass the interior of the mods I made.

A wire wheel rips it apart in record time.

[thebrassnuckles]

So, no real Flippac progress in the past months, but weather is beginning to get to be optimum fiberglass weather. So that a plus.

I finished painting my front bumper, and decided to do something about the ugly smashed in rear quarter panel.

So I beat the hell out of it with a BFH, then I got my hammer and dolly set in there. It looks quite a bit better. I then decided that in order to get it looking a lot better, I had better get all that chipped paint off. So I grabbed my wire wheel and proceeded to take off several layers of..... My thumb.

Ouch.

[JasonRedwood]

Everyone likes picts...

[thebrassnuckles]

98981

Zombie thumb?

[JasonRedwood]

Hahahaha nice!