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

[Pacer]

Someone with actual race experience will know better than me....
What kind of fuel mileage are you getting with the with the truck currently?
Divide that in half to account for race conditions and then calculate how many miles you will need between fuel stops....

 

[YMT]

I have no racing experience, but a quick search I did found several options. No clue about quality or if they qualify.

Fuel Cells - Baffled

 

[matzell]

Put in the biggest tank that will fit! I had a 22 gal in my last car, I put a 32 in the new one. Sucks to have to stop and fill up if you are in the lead. Depending on the course, high range low range but figure about 3 miles per gallon. Some races I get less than that, others like KOH were there is more desert I get closer to 5.

Go to Alltech motorsports for baffling.

Home

Put two pumps in the tank. Outside they cavitate too much and do not run as cool. I use a dual phantom tank:

Dual Rail EFI Return Kit – Phantom 340 – Aeromotive, Inc

Most races are in the 50 plus mile range so you do not want to run out or low on fuel and starve the system on a long hill climb or trying to get up something.

 

[Charles4x4]

Put in the biggest tank that will fit! I had a 22 gal in my last car, I put a 32 in the new one. Sucks to have to stop and fill up if you are in the lead. Depending on the course, high range low range but figure about 3 miles per gallon. Some races I get less than that, others like KOH were there is more desert I get closer to 5.

Go to Alltech motorsports for baffling.

Home

Put two pumps in the tank. Outside they cavitate too much and do not run as cool. I use a dual phantom tank:

Dual Rail EFI Return Kit – Phantom 340 – Aeromotive, Inc

Most races are in the 50 plus mile range so you do not want to run out or low on fuel and starve the system on a long hill climb or trying to get up something.

Thanks. I'm definitely going to Alltech for baffling. I'll do some measurements as soon as we tear out the interior (the DD is almost done - so it's coming soon) and see how big of a tank we can fit.

That Phantom 340 kit looks amazing. I'm not sure I can fit it in the budget. I've already got a nice single kit from URD that we're going to try to use some of but definitely want to run dual pumps.

 

[Charles4x4]

Update: I'm close to being finished with the DD - maybe 2-weeks left - then I can stop driving the 4th gen and the true tear-down begins. More updates below:

In Process:
- Front Suspension and Steering are being fabricated
- Front RCV Front Axle Shafts are being engineered
- Rear RockSolidToys 4-Link Suspension brackets are completed
- Rear Currie RJ60 is being made (not sure if they have done gearing or not yet)
- AEM Fuel System gauges (2) likely go in this week

Still working on:
- URD MAF Calibrator in the mail
- Fiberwerx Fendres in the mail
- PRP Seats being ordered
- Locking down sponsors for Armor and Tires
- Lock down fuel cell dimensions and dual-pump system

I'm also struggling to find reasonably priced 4th gen salvage doors shells (4) and lift gate to gut. If anyone knows of any in the Southeast, PM me!

 

[Charles4x4]

Quick Update: Four salvage doors are being loaded on a pallet as we speak and will be go out tonight. Picked up all 4 shipped for less than 1 locally. Patience paid off big and allows me to put $ back into other parts of the budget.

More updates:
- Warn Zeon 10-S Platinum Winch in the mail
- URD MAF Calibrator in the mail
- Fiberwerx Fenders in the mail
- PRP Seats Ordered
- PRP Harnesses Ordered
- Solid progress on the Front Suspension and Steering this week

Will dive into fuel cell and system later this week. Special thanks to Matzell for his help with fuel setup suggestions.

Still looking to lock down my final tire sponsor. If you've got suggestions, PM me. I've got good pricing from one option already, but think we can get more.

 

[Charles4x4]

I've been out of town the past week, but here is a quick update on this build:
1) Our new Warn ZEON Platinum 10-S winch arrived yesterday. It's a thing of beauty and the remote will definitely come in handly for our co-driver at KOH!

2) I knocked out a few small projects, including swapping in a new O2 sensor damaged when we did the Y-Pipe cat delete (this 4.7L V8 is really squeezed in there). The new sensor eliminted the CEL I was getting. I'm still waiting on the URD MAF Calibrator to arrive and will install my AEM gauges before we do final tuning.

3) The Salvage doors arrive on Wed. Then I'll check out the internal bracing and see how much more we want to cut. I'm hoping they are really light in already gutted condition.

4) We are now only down to one sponsor need for tires. I've reached out to BFG, Goodyear, Maxxis, Nitto, Cooper, and Falken. So far Falken and Maxxis have shown strongest interest.

5) I've finalized plans with two additional sponsors. More to come on these in a few weeks.

Finally, the DD should be back from paint by the end of next week at the latest and ready for reassembly. As soon as it is done, the interior tear-down on this one will begin along with the doors and front fenders. Then the transformation will really begin to take shape. Thanks for your patience.

 

[Charles4x4]

I thought it may help to give a glimpse into the behind the scenes a little more. If you're only watching this thread for the hardcore stuff that is yet to come, skip this post.

From what I know so far, here is what it takes to make something like this Steel City Racing KOH project happen! Since I really committed to this build in May, I've spent a lot of time:
- Reading the Ultra4 rulebook 3-4 times and making lists of everything I have to get done to pass tech and stay within the 4600 class rules
- Creating a budget and a "dream build" list of To-Dos that fit the vision of this build and the 4600 class rules
- Pulling together the story of this project, which was critical for grabbing initial sponsor interest
- Filling out sponsorship paperwork, online forms, and legal documents - probably 50 forms filled out in total
- Building momentum with sponsors. Once you land 2-3, it does get easier.
- Landing sponsors, we are now up to 15 with 1 mandatory (Tires) sponsor remaining and 3 optional ones outstanding
- Creating relationships with groups like Marlin Crawler and RockSolidToys who believe in your vision and are willing to do whatever it takes to make it happen. Without BigMike and Wyatt in particular - and their willingness to connect us with others in the industry and build amazing parts for this rig - this build would be tough!

In today's age, the currency is no longer build-threads on forums. I'm doing build threads like this for ideas, diversity of thought, and because I think they are mostly extinct today which is a shame. Instead, it's social media that brings sponsors to the table. So, I had to:
- Create a rendering of how the vehicle will look
- Create social media campaigns for Facebook and Instagram (more time consuming than I had expected)
- Get the word out on forums, family & friends, and with Toyota enthusiasts.
- Constantly post new content to keep the interest (tough some days)

I then was finally able to get rolling - so, I started
- Looking for a no-rust, low mileage, affordably priced 4th gen v8 4x4 Sport or Limited (much harder to find than expected)
- Finishing my DD so I can tear into this one (still have a few weeks left - it's in Paint now)

We entered Phase I - Engine Performance, which I could do while the DD wasn't complete:
- Install Magnaflow exhaust, URD y-pipe with cat delete, new Denso O2 sensors, aFe Power air intake, URD 170 degree thermostat, AEM AFR and Fuel Pressure gauges, Doug Torley Headers (not yet installed), and URD MAF Calibrator (in the mail)

At the same time, I am still acquiring parts:
- The Warn ZEON 10-S Platinum winch arrived
- Fiberwerx Fenders are in the mail
- Front seats and harnesses are in the mail (seat brackets arrived)
- Salvage doors arrive on a 18-wheeler today (still looking for a liftgate)

Once the DD is done in a few weeks, I can tear out the 4th gen interior and remove exterior stuff, remove the stock doors, start on the fuel system, and work on armor (more to come here with a sponsor I just landed on Monday).

As we speak, the following is also in process:
- Rear RJ60 is ordered and being built
- Front suspension prototype should be complete in the next 2-4 weeks
- Front steering prototype is on the same timeline
- Front RCV Next Gen axle shafts are being engineered but won't be ready till the Fall
- Rear bumper prototype is being engineered and will be ready in the Fall
- Atlas II is being ordered
- Rear 4-Link is done and ready to be installed once the front suspension is on
- Coilovers, Coils, and Shocks are ready to go once the suspension is on
- Tires (still need a sponsor here) and Wheels will be ordered
- Driveshafts are envisioned and final specs will be dialed in once the suspension is on and final angles/measurements can be taken
- Roll cage is envisioned

All of that while balancing family life and running a small business. Note that the 4runner will be in CA for the real fabrication, starting in August.

So, if you're just looking at pictures, I think you may not be seeing the full story of what all has gone into this build thus far.

Lastly, as a shameless plug, if you want to help this build to keep up momentum with happy sponsors, please follow it on IG and FB and tell your friends. We need more followers - which will come from word of mouth from forum members like you and with momentum once the "sexy" fabrication side of the build really takes off. Social media is today's sponsorship currency, period!

And please PM me with any ideas or contacts you may have for Tire Sponsorship!

 

[Charles4x4]

More parts arrived today! These Fiberwerx front Fiberglass 4.5” Bulge fenders will really help us for the 35s while keeping COG low. I plan on installing them when the salvage doors are ready (should be here next Wed).

 

[mr jits]

How are you planning to mate the Atlas to the Toyota transmission?

 

[Charles4x4]

How are you planning to mate the Atlas to the Toyota transmission?

AA makes an adapter for the A750F.

 

[mr jits]

AA makes an adapter for the A750F.

I wish I'd known this starting my 40 build. There was a guy selling marine 4.7's for a song, and I could have kept a Toyota heart in the little truck.

 

[Charles4x4]

Took measurements of the cargo area stripped down for the fuel cell and spare tire last night. I'm thinking fuel cell on the platform just behind the rear seats today (removed for KOH) and spare standing straight up or slanted 45 deg toward the front over the rear portion of the cell.

The fuel cell area behind the seats is 42 W x 26 D.

The spare tire area behind the cell before the liftgate is 58 W x 14 D

Max vertical height 39" in center, min right at Liftgate 35.5" - will likely gain another 1" with full teardown.

We'll be using Alltech baffles - no foam. Researching fuel cells later today.

 

[Charles4x4]

Put in the biggest tank that will fit! I had a 22 gal in my last car, I put a 32 in the new one. Sucks to have to stop and fill up if you are in the lead. Depending on the course, high range low range but figure about 3 miles per gallon. Some races I get less than that, others like KOH were there is more desert I get closer to 5.

Most races are in the 50 plus mile range so you do not want to run out or low on fuel and starve the system on a long hill climb or trying to get up something.

So, I haven't had a ton of time to search, but there seem to be really cheap and really expensive fuel cells. Jaz Pro Sport II seems to be right in the middle with good reviews.

Wide & Short 22 Gal (34-1/2"L, 18-3/4"W, 10-1/2"H):
JAZ Products 280-122-NF: 22 GAL. PRO SPORT 2-1/2 NO FOAM | JEGS

Wide & Short 32 Gal (34"L, 17-3/8"W, 14-3/8"H):
JAZ Products 280-032-NF: 32 GAL. PRO SPORT 2-1/2 NO FOAM | JEGS

I can fit either and Artec makes a nice mount for both. I can see the need for a 32 Gal cell with a big LS that gets 3-4 MPG. But we're using a slightly modified 4.7L Toyota V8 - Maybe our MPG is 2-3x this?

- Is the extra capacity of the 32 Gal needed and worth the extra weight?
- Is there high probability that I'm going to need more than 22 Gal between pits at KOH or other Ultra4 races, Mint 400, or even Baja if that dream ever comes true?

I'm good with Matzell's advice on the 32 Gal, but wanted to ask simply because of our mostly Stock Toyota v8 vs. a much more powerful and less efficient engine.

 

[Charles4x4]

Stock 2016 V8 MPG is 17/20. Cut that in half for race conditions and power modifications we've done. Maybe 8-10 MPG. 5 MPG worst case scenario.

- 10 MPG and 22 Gal = 220 Miles
- 5 MPG and 22 Gal = 110 Miles
- 10 MPG and 32 Gal = 320 Miles
- 5 MPG and 32 Gal = 160 Miles

2018 KOH Total Distance:
4400 = 202 Miles
4500 / 4800 = 136 Miles
4600 = 124 Miles (us)

Given the Main and Remote Pits - Even at 5 MPG I don't see how I need more than a 22 Gal cell right?

If I ever get to race it at Baja, that's a great excuse to upgrade to 32 Gal.

 

[mr jits]

Stock 2016 V8 MPG is 17/20. Cut that in half for race conditions and power modifications we've done. Maybe 8-10 MPG. 5 MPG worst case scenario.

- 10 MPG and 22 Gal = 220 Miles
- 5 MPG and 22 Gal = 110 Miles
- 10 MPG and 32 Gal = 320 Miles
- 5 MPG and 32 Gal = 160 Miles

2018 KOH Total Distance:
4400 = 202 Miles
4500 / 4800 = 136 Miles
4600 = 124 Miles (us)

Given the Main and Remote Pits - Even at 5 MPG I don't see how I need more than a 22 Gal cell right?

If I ever get to race it at Baja, that's a great excuse to upgrade to 32 Gal.

I really think you're overestimating your MPG figures as well as ignoring some sound advice from @RustyNailJustin in that you need to install the largest fuel cell that will fit. You will not regret having extra fuel, but you'll certainly regret running out or needing to pit more often.
The 4.7 is not more fuel efficient than the LS engines in a WOT scenario. In fact, the 4.8 and 5.3 LS flow at 24.8 lb/hr and the Toyota 4.7 is at 26.2 lb/hr. I'd plan on using the larger tank.

 

[Charles4x4]

I really think you're overestimating your MPG figures as well as ignoring some sound advice from @RustyNailJustin in that you need to install the largest fuel cell that will fit. You will not regret having extra fuel, but you'll certainly regret running out or needing to pit more often.
The 4.7 is not more fuel efficient than the LS engines in a WOT scenario. In fact, the 4.8 and 5.3 LS flow at 24.8 lb/hr and the Toyota 4.7 is at 26.2 lb/hr. I'd plan on using the larger tank.

Maybe 5 MPG is generous? I’m definitely looking for veteran advice. But I’m also getting mixed feedback.

Example: Just had a KOH racer in Pirate suggest a 22 GAL - evidentially he ran a 12 GAL last year and had no issues. Believe me, I’m hitting Justin up often for advice .

If the weight difference of 10 GAL (~60 LBS) isn’t a big deal and the added height doesn’t affect my spare tire placement, better be safe than sorry. But if I can comfortably get away with 22 GAL under Worst Case Scenario MPG... I just don’t know enough to know what worst case scenario is in race conditions.

 

[mr jits]

Maybe 5 MPG is generous? I’m definitely looking for veteran advice. But I’m also getting mixed feedback.

Example: Just had a KOH racer in Pirate suggest a 22 GAL - evidentially he ran a 12 GAL last year and had no issues. Believe me, I’m hitting Justin up often for advice .

If the weight difference of 10 GAL (~60 LBS) isn’t a big deal and the added height doesn’t affect my spare tire placement, better be safe than sorry. But if I can comfortably get away with 22 GAL under Worst Case Scenario MPG... I just don’t know enough to know what worst case scenario is in race conditions.

When I used to do a lot of drag racing, I'd use between a gallon and a gallon and a half each quarter mile pass (warm-up, pass, and return track) with N/A 4.6l. I'm not sure of how well that will equate to ultra 4 style racing, but I think 4-5mpg as you're thinking isn't a stretch. How long are the races? How often do you want to pit? Those would be the deciding factors for me for tank size.

 

[Charles4x4]

Maybe 5 MPG is generous? I’m definitely looking for veteran advice. But I’m also getting mixed feedback.

Example: Just had a KOH racer in Pirate suggest a 22 GAL - evidentially he ran a 12 GAL last year and had no issues. Believe me, I’m hitting Justin up often for advice .

If the weight difference of 10 GAL (~60 LBS) isn’t a big deal and the added height doesn’t affect my spare tire placement, better be safe than sorry. But if I can comfortably get away with 22 GAL under Worst Case Scenario MPG... I just don’t know enough to know what worst case scenario is in race conditions.

Details above - 4600 last year was 123 Miles but lasted 7-8 hrs or more. I don’t know distance between pits, but recall none more than 40-50 miles apart (Main + Remote 1, 2, etc).

If it wasn’t for the spare being tight, I’d just do the 32 Gal and if we don’t use much, we simply don’t fill it up.

 

[matzell]

I just got back from the Dirty Turtle race in KY. We did a pre-run lap in the mud and one qualifying lap. Plus some idle time. less than 8-9 miles total. I burned 7 gals of fuel. I have not filled the car since the race to find out how much we burned.

I got about 3 mpg with a 4.3 v-6 in my last car.

You can cut the floor and sink it down to the frame, or between the frame to give you extra room.