Build Ideas/Questions

I’ve currently got my 4Runner body taken apart for painting and for me to fix some frame rust, and I’ve been brainstorming on what mods I want to do.

The OEM plastic running boards have faded with time, and I am debating replacing them with tube steps or just doing a step delete as I don’t use them often.

This winter I will also be fabricating my own tube roof rack like the ones on 5th gens for my camping and off reading escapades, as the standard luggage rack isn’t cutting it and I’m not paying 1000+ for something I could make with equal quality in 2-3 weeks when my uni is on break.

However I am also looking at getting a bull bar because deer and other small animals (raccoons, possums, etc) in Ohio are not fun to hit. Regardless of which I choose to do, I’ll get them with a black powder coat. Do y’all think that if I do all 3 tube mods it would be too much tubing and would look trashy, or would it have a more off road look? I’ve attached photos that get a good idea of all 3 that I am contemplating:


Also are there any good or simple quality of life improvement mods that I should know about or do to mine on top of what I am already contemplating? I’m putting a light bar in the sport hood I found with a scoop, and putting a spoiler onto the new rear hatch as the old sr5 hatch has rusted out.

 

Bull bars in general do NOT provide good protection for a deer hit. Most are not secured by much other than a weak mount system and end up causing more damage upon impact. The side bars are more cosmetic also. The roof rack is probably the 1 thing of the 3 that will be user friendly.

 

Do you mean more cosmetic in my case as I rarely use them, or that they are not meant to be load bearing? They’ve got a load rating of 400 lbs and reuse the current mounting areas, but I don’t even know how I’d manage to get anything anywhere near that on one of them.

Do you reckon that a bull bar would be useful for going through light brush work, or would it still just be a cosmetic liability/dead weight? Would likely use it for off roading or during hunting season at a family property deep in the woods. In that case if it’s still just going to provide problems with no benefit, would it just be better to make a skid plate or something?

 

For what it’s worth, I’d suggest taking a look at what people have actually done to their vehicles who take them properly off road.


You’ll notice some trends that run counter to your thoughts on the steps and bull bar.

That’s going to be more productive than guessing what will work.

Trail4Runner also has a lot of good info on products you might consider.

 

So for me, I’m most of the time using my 4Runner as a daily driver as well as something to haul my boat or trailer, plus occasional lumber. The off roading/camping is mainly on the weekends or during hunting seasons. Do you know any build threads in particular that manage to balance off road effectiveness with daily driving efficacy?

 

For what it’s worth I’ll have to do something about the current steps. Looks positively hideous with all of the sun damage. I’ve just now realized I can’t do a step delete as I do need something to be able to stand on while attaching stuff to my luggage rack and in the future roof rack.
If not tube steps (the cheapest option I was able to find), what do you all recommend?

 

If it's primarily a daily driver, with minimal off-roading, I'd avoid a big lift, and try to stick with stock size tires. I'd also recommend sticking to an SL tire, unless you want extra durability or puncture resistance.

Step bars can get in the way off-road. But, if you're not going to be in the rocks, they're probably fine.

The PRO rack doesn't look super useful to me. You might want to look into other types of racks people have bought or built.

 

Just shield your eyes when people start talking about lifts and bigger tires, and you’ll be fine.

Maybe add some skid plates, and for steps get some slider steps that bolt to the frame rails. That way, if you do hit something with them, you don’t have to worry about body damage.

As for bumpers, I think it only makes sense if you are going to mount a winch. I have yet to see a bumper that doesn’t involve cutting, and so think of it as a one way ticket.

In terms of racks, get something low profile that you can add to when you need it. Otherwise you are just pushing extra air around, which is horrible for mpg and performance.

 

Good point about the roof rack. I have actually tested this, and I lose about 10% fuel economy on the highway with my current rack. That's also why I made it removable.

 

I’m in the very early stages of design, and I do apologize for the poor penmanship, as I’m still trying to regain full use of my fine motor skills. As I reach more final designs that I am happier with and take measurements, I’ll probably model it in some sort of CAD program or other 3D rendering software. Trying to design something that can hold some of my camping gear + a jerry can of fuel and water each, but also something that I could easily slide in most lumber and be able to strap it down. This is my best design yet.
It will for sure be removable, as I already only get like 16 mpg and do not need that to be worse. Designing it to use the old luggage rack mounting system too.

 

Don’t forget to consider commercially available options, and factor in the cost of your time when comparing.

In many cases, it’s cheaper to take advantage of economies of scale.

 

I would look at low profile rack options if you have mpg concerns.it would suck to take off and put back on regularly.

 

Sorry about the delay on getting back to you. (the work thing got in the way) I've had some side bars on pickups. Being from Ohio I'm sure you see salty roads in the winter. While the side bars might hold up for a few years, the salt will eventually take it's toll. I was reminded of this when I heard a dragging sound on the road one day. (side tube/bar rotted off) There are better alternatives. Going through light brush and a bull bar, don't really see an advantage to having a bull bar for brush, I'm probably wrong but, you're going to get "pinstripes" from the brush, so it won't hurt. As far as roof racks, Thatbassguy has the mileage thing down to a science, like he said with the roof racks.

 

Oh, that would be problematic. Salted roads + summer humidity had taken a heavy toll on my frame and caused me to have to weld in a bunch of metal already.
You reckon I’d be better off just somehow refinishing the current plastic? I’d contemplate making my own then out of aluminum to prevent rusting, but that’s a lot of work and aluminum is a major PITA to weld in my experience.
You know of any alternatives aside from that or an outright step delete?

As far as the bull bar goes, you think it’ll suffer from the same rust problem too?

 

Make the aluminum ones when you can, it would be the effort. As far as the bull bar, if it's made out of steel, it can rust, all I'm saying is a bull bar, generally does not offer the protection from a deer hit, and may cause more damage. There are very few bull bars that might have secure mounts to the frame and appropriate bracing as to not collapse during such an encounter.

 

I had the same problem with the plastic trim on my old Xterra. I highly recommend DupliColor Trim & Bumper paint but you must do good prep following their directions.

Looked great and still did when I sold the truck several years later. I popped that top bumper piece off, painted and replaced it, then took this pic to show the difference. Truck looked new once I got it all done.




Edit: Here it is years later when I listed it for sale.



As for the bull bar, it will rust like anything else if not protected. Check it regularly and hit any scrapes or nicks with rust reformer paint before they spread.