Builds Steel City Racing: King of the Hammers 2019 Toyota 4Runner IFS 4600 Build Thread

Discussion in 'HardCore Corner' started by Charles4x4, Jun 19, 2018.

  1. matzell

    matzell SILVER Star

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    The color has to be the color code U4 supplies, not just some random spray can color.
     
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  2. Pacer

    Pacer SILVER Star

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    Pearls of wisdom :idea:
     
  3. Charles4x4

    Charles4x4

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    I was hoping to get PMS 2707 C in an aerosol can. I assume that is what most do.

    [​IMG]
     
  4. cruisedeisel

    cruisedeisel Toyota's for life

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    Forgot I was on IH8mud for a second there. I though I was shopping on amazon.
     
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  5. Charles4x4

    Charles4x4

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    LOL, patience :)!
     
  6. Charles4x4

    Charles4x4

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    Here are the first glimpses of our 2" DOM Roll Cage from Robert Otwell at Otwell Welding and Fabrication.

    Note we haven't begin tying it into the Frame, adding Horizontal Supports (A to B Pillar, etc), Gussets, Cargo-Area Work, etc. This is just the general outline at this point, so know there is much more "strengthening" to come.

    Stripped and Ready:
    [​IMG]

    A to D Pillar:
    [​IMG]

    [​IMG]

    B-Pillar Placement after some "Tweaking" it to fit nicely:
    [​IMG]

    [​IMG]

    First Draft Front Seat Placement:
    [​IMG]

    Initial Dash Bar Placement:
    [​IMG]

    [​IMG]
     
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  7. Charles4x4

    Charles4x4

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    Overhead Structure:
    [​IMG]

    The Rear Seats Backs are in there for placement of the Fuel Cell Firewall. They will of course come out very soon:
    [​IMG]

    First glimpse at Windshield Frame Visibility:
    [​IMG]
     
  8. BMThiker

    BMThiker I aim to misbehave Moderator SILVER Star

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    Is there a stock class requirement to leave the rear seats in place?!
     
  9. Charles4x4

    Charles4x4

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    While Otwell is working on the Roll Cage, RockSolidToys is busy prepping the Atlas II for Transplant!
    [​IMG]
     
  10. Charles4x4

    Charles4x4

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    No, we're just using them to help place our Fuel Cell Firewall. They'll be pulled soon...
     
    Last edited: Jan 10, 2019
  11. Charles4x4

    Charles4x4

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    Here are the final pics from work completed last night:
    40+ Gussets made from 1.25" x 0.120 DOM:
    [​IMG]

    Starting on the structure for where the Fuel Cell Firewall, Fuel Cell, Spare Tire, Spare Tools, etc will be mounted.
    [​IMG]

    Note this is not part of the Main Structural Cage. However, the bottom horizontal bar is actually wider than the Frame just below the floor, so in the event of a roll over, it would actually provide structural support which is nice.

    From here, a Lower Shelf right at floor level will be built for the Fuel Cell.

    Then Fuel Cell Firewall will go from side-to-side across the back and up 2" above the cage along the same plane as the rear seats (they are still in there for mock-up purposes).

    Then a Upper Shelf will be built over the cage that will hold the Spare Tire horizontally above the fuel cell (it won't fit any other way).
    We'll then install PowerTank, Spare Tools, Ammo Cans, etc on this shelf structure and the D-Pillars.

    We initially hoped to mount the spare behind the fuel cell on a 30deg or 45 deg angle, but we don't have enough space. We can't stand it up 90deg as it would block our view out the rear view mirror. It also tried Left/Right, but no go.

    8.2.11.10
    A rear view mirror is required on all vehicles. Mirrors must have at least six
    square inches of mirror surface. Mirror must have a reasonably unobstructed view of area behind vehicle.
     
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  12. Charles4x4

    Charles4x4

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  13. mr jits

    mr jits SILVER Star

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    Why isn't the cage hugging the roofline, why is there no triangulation at the B pillar? I get you're putting in gussets, but you need triangulation at the B pillar in case of a rollover at speed.
    Also, you are cutting this terribly close if you're expecting any opportunity to run it before race day.
     
  14. Charles4x4

    Charles4x4

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    It will be hugging the roofline after today (we were trying to make a slot to squeeze the sunroof back in - but scrapped that idea today).

    There will be tons of triangulation at the B Pillar.

    Yes, we're doing the best we can. I hear we're not the only KOH team cutting it close :)
     
  15. Charles4x4

    Charles4x4

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    Roll Cage Update:
    Here's where we ended up for the night. As you can tell, the feedback I received today from all the forums made a significant impact. I'll let the pics tell the story.
    [​IMG]

    [​IMG]

    Robert Otwell has been flying. He said "everything has just been falling into place really nicely!". So much so that he asked me to move up my flight by 3-days to tackle all the Small Stuff earler than expected while RockSolidToys is finishing their work.

    I'll now be at Otwell's shop starting MLK Day - Monday 1/21! This should give us more days for testing! Thanks again for all the advice and feedback today and I hope everyone has a great weekend.
     
  16. matzell

    matzell SILVER Star

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    I am still waiting to see how you tie the cage into the frame...roof lines look much better.
     
  17. Charles4x4

    Charles4x4

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    Thanks. There will be plates sandwiched together at the floor on both sides. Otwell has been staring at the frame routing since day 1 - so I don’t know the exact layout of the tie-ins but he does.

    Should be done with all frame tie-ins next week.
     
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  18. Charles4x4

    Charles4x4

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    Update on yesterday's progress:

    Otwell dropped the cage through the floor for finish welding, including on top of the cage.
    [​IMG]

    [​IMG]

    Robert made good progress on some of the more complex joints:
    [​IMG]

    [​IMG]

    And we got our T-Shirts made for our core 4602 and Pit Crew teams. I couldn't get sponsorship on this, so we didn't get many extras made. Maybe next year!
    [​IMG]

    [​IMG]

    We might also have some helping hands from @RustyNailsJustin and members of his 4619 team come down to Otwell's shop late next week to help out with the pile of "small stuff" which would be a HUGE help!
     
  19. Charles4x4

    Charles4x4

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    Update:
    Over the past 2-days, Otwell has been knocking out our Frame Mounts (this took a TON of effort), side protection bars, and vertical windshield bracing. I'll let the pics speak for themselves:

    Current Helmet Headroom on 5'11" Person is 4-5":
    [​IMG]

    Frame Mounts using Grade 8 1/2" x 2" Hardware (All 3 on Passenger Side shown):
    [​IMG]

    [​IMG]

    [​IMG]

    Interior Sandwich Plates to Frame Mounts:
    [​IMG]

    [​IMG]

    Side Protection Bars (set at top of Seat Cushion height):
    [​IMG]

    Random B-Pillar Floor Brace to show where seats will likely end up. Note Otwell is making the mounts to tilt the seats back 10deg back for comfort and visibility reasons:
    [​IMG]

    I was able to borrow a GoPro Hero 4 Black from a friend and picked up (2) 128 GB MicroCards so we can hopefully record the full race. This will be mounted using a GoPro 1.5" to 2.5" Roll Cage mount - likely on the Dash Bar:
    [​IMG]

    Finally, I finished sync'ing our Dual XGPS160 to the iPad Pro, downloaded LeadNav Software, and purchased the LeadNav Pro Pack Annual subscription. For navigation, I really can't do anything else till the Course Maps are released on Friday 2/1 at 8pm PT from PCI Race Radios. We plan to start pre-running on Saturday 2/2.
     
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  20. Charles4x4

    Charles4x4

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    Our team is excited to announce another sponsor: Pro Eagle Jacks. We'll be running their 2 Ton "The Beast" Big Wheel Jack and Bed Mount on the car at KOH.

    The Beast:
    [​IMG]

    Bed/Floor Mount:
    [​IMG]

    After speaking with Hobie about this a few weeks back, we both felt a Pro Eagle was the right choice for KOH. It does weight a bit more, but is much safer, faster, and more compact than alternative Scissor, Bottle, or Hi-Lift Jack options.

    Let's hope we don't have to use it during the race!

    My Co-Driver for EMC, Matt Tatum is a Professional Firefighter and Paramedic. He handled our First Aid Kit - the bag is from Rago Fabrication:
    [​IMG]

    [​IMG]
     
    Last edited: Jan 17, 2019 at 12:31 PM
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