rustED71's 1991' Ex-cab Build (2 Viewers)

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Bummer!!! I’m in a similar boat. Head issues... don’t skimp when purchasing a new head. Buy one from 22re performance or a OEM. Trust me, you will be pulling your engine apart after 20k to redo what you could have prevented. Also, why didn’t you pull your engine?? Soooo much easier to disassemble and reassemble on the bench, especially if you are doing that extensive of a rebuild. Make sure to use a quality head gasket too...
Yeah I've been pricing heads, I dont want to skimp either, all the parts i have bought so far have been either from LCE Performance (headgasket kit) or 22RE Performance but I dont have $600 to $1000 to spend on a quality head now with the quarantine going on.

I didnt pull the motor because I dont have a engine hoist, I agree it would have been alot easier. At this point I'm considering buying one and pulling this motor out and dropping in the 22re out of my 87 4runner. It runs like a swiss watch but the body is beat and interior is gutted. I'll stick the original motor away on the back burner until I can afford to finish what I started... at least I'd have my truck going again I'm missing it!
 
The swap out of the 4Runner sounds like a good plan. Then build up the other one for your FJ40 hybrid project.

How are you doing with the whole lockdown thing? It’s a crazy world right now. I’m usually in Washington 2-3x per week, and haven’t been able to cross the border in almost a month. It looks like it will be at least another month before it re-opens.
 
The swap out of the 4Runner sounds like a good plan. Then build up the other one for your FJ40 hybrid project.

How are you doing with the whole lockdown thing? It’s a crazy world right now. I’m usually in Washington 2-3x per week, and haven’t been able to cross the border in almost a month. It looks like it will be at least another month before it re-opens.
It's good to hear from you! I think that's my new plan. I just went up and got my 4runner yesterday, it was stored up at my parents house where I used to live up by Republic ( I now live in Yakima). After sitting for almost 2 yrs it made the 5hr trip with no problems. The motor seems like it has alot more power pulling hills and maintained its cruising speeds on hills without having to down shift compared to my 91'. The pickup has always felt gutless (even when I first bought it and it had the smaller tires) which seems weird with how low of miles it had. If you are still interested in the hard top from the 4 runner I'll keep that for you.

I'm doing pretty well with the lockdown, havent ran out of TP yet so that's good, lol! Now that I have my 4runner I can start working on the truck again. I also got a bunch of my tools and my beadroller so I can start doing some sheetmetal work on the side. I might start doing some door cards again to make a little $$ on the side to supplement some our lost income. Glad your doing well, I didnt even think about the borders being closed.
 
I’m definitely still interested in the top.

We were supposed to go to Pismo Beach for the vintage trailer show on May 14-16 but they say there is no chance they will lift our restrictions before May 1st, and we are in way better shape than Washington as far as virus numbers, so I doubt the border will be open again before the 10th when we would start driving. Oh well.

It’s funny how some engines just make more power. My 80 series was like a rocket compared to others.
 
I haven't posted an update in awhile, but have been making some progress. I got my 87' 4runner from storage. It hasn't been driven much in the last 2yrs and hadn't been started all winter. I put a battery in and it fired right up. Checked the fluids, loaded it up with a bunch of tools and odds and ends from storage and drove it 5hrs home. It ran awesome all the way, not so much as a stumble. My fiance was following me and she said I was doing 80 on the interstate (speedo was off a bit with the 31's.) It pulled hills well and maintained speed alot better than my 91'pickup ever has. This all reaffirmed my decision to move ahead with my plan and just pull the motor out of the 4runner and stick it in my pickup.

So I bought an engine hoist and engine stand (to store the 91' motor until i can work on it). Since we dont have smog here I decide to do an EGR delete and eliminate the air injection. I kept the exhaust manifold on the 87' motor, it didnt have the air tube coming off the exhaust like my 91, this saved me from having to plug off the hole were the tube was. I used some 1/4" thick steel plate and made the 2 egr block plates. Here's a couple pics of them installed.
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And a pic of all the egr, air injection and vaccum lines that were eliminated.
 
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I got the truck fired up and running today. Seem to be running good, I thought I might have to chase down some vacuum leaks from the EGR delete, but it seemed to be running smooth. I forgot to plug in the oil pressure sender switch, so I didnt have any oil pressure on the gauge, scared me for a second! I didnt get to test drive it, still need the mufler/exhaust done. Here's a pic of the engine all buttoned up. I noticed the radiator overflow reservoir off of my 87 4runner was alot nicer, and after comparing the two I found out they were identical except for the metal mounting bracket is longer on the 91'...so I swapped the brackets and put the nicer non-yellow overflow tank in the pickup. I would have like to have cleaned and detailed the engine compartment a little better, but I need to get it on the road and my " honey do list" is growing again lol.
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I forgot the valve cover sticker, put that on today. So far the machined aluminum half moon gaskets are doing good, no leaks yet. I did find a leaking coolant line on the IACV on the bottom of the throttle body, fixed that. I have a check engine light on, jumped the diagnostic port and I have a code 52 ( knock sensor). Not sure if that would have anything to do with the EGR delete?...need to look into that, didnt seem to affect its driveability, i put 40 + miles on her today and she ran pretty good. It felt good to drive her again, it's been almost 4 mths since I parked her.
 
Trying to keep busy since I've been off work. Decided to swap in some leather bucket seats. My original plan was to keep the inside of the truck stock and possibly getting the original bench reupholstered, but it isnt very comfortable on trips. I also wanted some larger cupholders. The ones in the dash come in handy but anything larger than a pop can can't fit and and also blocks the Heater/Ac vents. So I decided to build a center console with cupholders. This one is a little different, I dont need an armrest since my bucket seats have swivel armrest built in. So I had to make a low profile console that wouldn't interfere with that. I think I will put a small storage compartment in the center, just a shallow one for sunglasses and small items. Here's a few pic of the center console (not finished and in mockup stages) and the seats that
I will be installing.

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Looks great . Maybe I missed it but where are those captain chairs from? And would your center console fit in a 2nd gen 4runner?
Thanks, the seats are out of a 2006 Honda CRV. They are comfortable but took alot of modifying because they sat up to high, especially the driver seat because it had a height up and down adjustment. I originally modified these and built new mounting brackets to fit them in my 87 4runner and they driver seat still sat too high, I'd always bump my head on the ceiling pillar getting in and out. But in my pickup they sit lower and it seems very close to factory height. Now I need to redo the passenger mount because the holes dont line up. 🙄

I've never owned a 2and gen 4runner, but I'm guessing it would fit. Its aprox 34" long and only 5" wide and 4-1/2" tall. I made it shorter to clear my seat armrests. I'm still playing around with the design.
 
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Didnt have much time today but I did get my new to me digital clock installed...its the little things in life 🙃...

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by the way I have a digital clock out of my 87' 4runner if anyone is looking for one. It works well, the face might need a little buffing tho, I'll let it go for free if whoever wants it springs for shipping...(*Edit...clocks going to a new home).
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So... when are you going to start making/selling those center consoles? It looks great. I mean, it's not in the same category as that digital Quartz (!) clock, but really, few things are.
 
So... when are you going to start making/selling those center consoles? It looks great. I mean, it's not in the same category as that digital Quartz (!) clock, but really, few things are.
Ha, ha! yeah it's hard to upstage one of those quartz clocks! I've always been amazed at how truly accurate they are tho.

Thanks on the console. I've made a few in the past, this one is pretty basic, just changing up the look on this one...its kinda got me rethinking my whole interior now tho. My door panels are in real good shape, but I'm thinking of making some to match the console. Here's some of the work I've done in the past.
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Finally put the finishing touches on the cupholder/console. I primed and painted the angle
frame, I like the brushed metal finish so I clear coated it so hopefully it wont rust, I also added black mesh behind the dimpled holes (hard to see in the pic). I beveled the edges of the HDPE top, and painted the self tapping screw heads to look like copper rivets.
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Its been awhile since my last update. I've put approximately 18,000 miles on the truck since swapping in the 22re from my old 87 4runner and the motor has ran great without any issues. My wife and I have recently gotten into kayaking so I added a Thule rack to the old canopy and some kayak roof rack mounts. I also replaced the broken rear window and replaced the worn out struts. Next up on the list is to build a sleeping platform for some upcoming camping trips.

I also picked up a another set of factory aluminum wheels with some Yokohama Geolander MT 31x10.50 tires. I got them from my dad with only a couple hundred miles on them. I plan on stripping the plastic clear coat off and painting them a metallic Grey Graphite color.

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After purchasing our kayaks I adding some T- rails for mounting accessories on them, and I really like the adjustability that the rails offer. It got me thinking about the interior of my truck. I've been wanting a cellphone holder for awhile. I haven't had one since last year when my truck got broken into and they stole it. I really wanted a solid mounting solution rather than using a suction cup attachment again. So I bought an 8" long Yak attak T rail that is almost the exact width of my cupholder tray. I reluctantly drilled 3 holes through the cupholder tray to attach it. Overall om pretty happy with the install. The cupholder functions as normal and my cell phone is in a good position that I can use google maps without taking my eyes of the road. I think up next for interior mods will be custom door panels and a new center console that incorporate some molle panels.

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I finished painting 2 wheels over the weekend, and am still working on stripping off the original plastic clear coat on the other 2, its a slow going process , im basically just using a wire wheel on my grinder. Here is a before and after pic of the wheel color...I am really liking it and cant wait to get these mounted on the pickup!

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