Stock Roof Reinforcement Tech (3 Viewers)

[RivMan]

Hey folks!

I wanted to start a thread to archive some information I found while researching a sunroof delete for my 80.

I couldn't find anyone that had done it sourcing OEM parts, and it took a lot of digging to put together a plan.

From my research there seems to be four different roof reinforcement combinations used on the 80 series. I'm guessing these correlate to a model year split, but I can't confirm that.

• Early non-sunroof
• Late non-sunroof
• Early sunroof
• Late sunroof

There also appears to be a crossmember that may be added for Rear AC equipped trucks (see below). Not sure on that, and didn't dig too deep.

I don't know the break point between early and late schemes, but the difference is that the later trucks received an additional rear reinforcement bar (#5 in the diagram). These diagrams are a little misleading, the added bar sits between the #3 bar, and the rear body frame #4. The parts diagrams show it between #2 and #3, that is not correct.

I won't be talking about the #4 bar at all, it's part of the body shell and seems to be the same throughout the 80 series run.

The #3 bar is identical in all 80 Series configurations I've looked at, both in part number and location.

Part numbers:

• Early non-sunroof
  • #1 - 63141-60010
  • #2 - 63143-60010
  • #3 - 63144-60010
• Late non-sunroof
  • #1 - 63141-60010
  • #2 - 63143-60010
  • #3 - 63144-60010
  • #5 - 63144-60010
• Early sunroof
  • The front roof skin has a double walled lip (roof skin and reinforcement) surrounding the sunroof, adding a lot of strength to the area. That lip transitions to a reinforcement plate behind the sunroof, bonded to the roof skin (See photo below)
  • #3 - 63144-60010
• Late sunroof
  • The front roof skin has a double walled lip (roof skin and reinforcement) surrounding the sunroof, adding a lot of strength to the area. That lip transitions to a reinforcement plate behind the sunroof, bonded to the roof skin (See photo below)
  • #3 - 63144-60010
  • #5 - 63144-60010

Here is a photo of the sunroof area of a US Spec 80 with a sunroof.

In my case, my truck was an early 80 with only a single roof reinforcement bar (#3). My goal was to delete the sunroof, install the OEM #1, #2 and #5 bars to match the later non-sunroof truck setup.

So far I've been able to source the #1 and #5 bars, and will know soon if I'm getting the final one (#2), or if I'll have to modify one to work.

• #1 - 63141-60010
  • Sourced via MegaZip
  • Seemed to be "in-stock" and shipped quickly from the Japan warehouse

• #2 - 63143-60010
  • The unicorn!
    • All US dealers show "in-stock" - none can actually produce one
    • MegaZip shows "in-stock" - but on perpetual backorder
    • ToyotaPartsDeal shows "in-stock" - claimed to have shipped it, never did, claim they cannot source it
    • Japan4x4 - Dave has ordered this through his sources and seems confident he'll have it in his hands next week
      • EDIT: DAVE IS THE MAN! He was able to track down this part!
  • EDIT: This bar is very close to the #3 / #5 bars, however it has a smooth top, there the other ones are contoured to match the roof strakes
    • The width and curve of the bar is identical to the #3 / #5 bars
    • The #3 / #5 bars are slightly taller at the ends of the roof skin, ~1/2"
    • Because of the way the bars have to be cut for installation, I believe a #3 / #5 bar would be completely usable for this application

• #3 - 63144-60010
  • This bar is the same part number as all #3 and #5 bars
  • It seems to be available for purchase new
  • My 80 was already equipped with this bar

• #5 - 63144-60010
  • This bar is the same part number as all #3 and #5 bars
  • It seems to be available for purchase new
  • I sourced one from US 80 Series part-out

These are the best photos (Credit @John Young and his Holy Truck build) I've found of the layout / installation of the bars. They are installed under the roof skin at the drip rail.

John's truck appears to have an additional bar between the #3 and #5 bars. I believe this is for a Rear AC system, but that's just a theory. I don't see it existing on any of the other sources I looked at.

This is a photo of an Early 80 with no sunroof. Note that it's missing the #5 reinforcement bar. (Credit @swankstar from his Locked 84 build thread).

I don't intend on removing the roof skin for this project, so my plan is to secure the ends between the roof skin and the body side rail. I plan to use a body panel adhesive (SEM 39747) to attach the bars to the body rail, and a vibration control material (SEM 39977) between the bar and the roof skin.

Bars #1 and #2 have divots in the body side rail that correspond to the location of the rails. There doesn't seem to be anything to locate #5, so I'll be going off the location in John's photos.

For the headliner, I found a set of non-sunroof bows on eBay, and purchased a new non-sunroof headliner from Headliner Mart - https://www.headlinermart.com/

Hope this info helps someone!

-Rob

 

[John Young]

Hi RM. I believe you're right about the aircon support member. The holy truck was a or rather is a 1997 just to fill in that blank. I also have a 1996 diesel 80 that just got a bunch of sound insulation and I may have some photos of that that show stuff from the inside. I will have a look. Incidentally, the holy truck is arriving in Savannah, Georgia. In a couple of days. My son and I are attending to drive it from Savannah to Las Vegas and then back to Florida. Essentially fresh off the boat. This may or may not be a good idea.

The rear aircon is something that for some reason they decided not to do in North America. But it's kind of common in Middle East trucks. Not quite sure about what goes on in Australia

 

[John Young]

Here are the first couple of photos that I found. This is from a 1996 omani diesel lady. I'm using voice dictating on my cell phone to do this. But I kind of like the idea of a diesel 80 lady.

I hope this is of some assistance

 

[RivMan]

Thanks, John!

Looks like both the 96 and 97 trucks have the extra roof reinforcement, as well as the rear AC crossmember.

Thanks!
-Rob

 

[John Young]

Thanks, John!

Looks like both the 96 and 97 trucks have the extra roof reinforcement, as well as the rear AC crossmember.

Thanks!
-Rob

My pleasure. Here's the actual video in case you want to look a little more.

 

[Squeegee]

This is neat. I just patched mine

 

[RivMan]

This is neat. I just patched mine View attachment 3905932

View attachment 3905933

That looks great!

Have you delt wit the headliner yet? Do you plan to trim around the patch and reinforce, or leave it as is?

-Rob

 

[Squeegee]

That looks great!

Have you delt wit the headliner yet? Do you plan to trim around the patch and reinforce, or leave it as is?

-Rob

I’m going to reinstall the stock headliner until I find a non sunroof one. The patch panel stiffened up the roof a little bit so I didn’t feel the need to reinforce it more

 

[RivMan]

Dave at Japan4x4 came through!

He has the unicorn #2 reinforcement bar in his hands, and it will be shipped out shortly.

-Rob

 

[Kernal]

It might help future MUD members if (after you receive the bar) you could measure the dimensions/angles/curvature of the #2 reinforcement bar (or better, get a 3D laser scan??). That way once it becomes completely extinct others may be able to reproduce it. FWIW

 

[RivMan]

It might help future MUD members if (after you receive the bar) you could measure the dimensions/angles/curvature of the #2 reinforcement bar (or better, get a 3D laser scan??). That way once it becomes completely extinct others may be able to reproduce it. FWIW

Excellent point.

I plan to compare it to #3 as well, to see if the brace that every US 80 series has is usable.

-Rob

 

[RivMan]

Here are some photos of the #2 bar next to a #3 / #5 bar.
The arch and width of the two bars match, however the "feet" of the #3 / #5 bar are slightly longer, making that bar ~1/2" taller overall. Because of the way you need to cut the legs in order to install the part, I don't see this being an issue at all. I would be willing to be that you could use the two interchangeably, as long as you flatten out the roof strake features.

-Rob

 

[Malleus]

Simply amazing...I can buy a roof panel body reinforcement for a truck that was manuafactured in 1996, but I can't buy a headlight glass. I'd give anything to talk to Toyota's buying stategists.