Internal Roll Cage 1st Generation 4runner

 So after years of wanting to do it I finally get motivated to have Bumpus build a roll cage for me.

Here's my 1985 4unner, the 4OD after I strip out all the factory stuff
 This is what I'm left with a thick layer of 24 year old carpet glue.
 Altho the carpet looked pretty decent when I started pulling it out I discovered it was covering years of desert trips, some broken glass random french fries and loose change. So I make the now easy choice to ditch the carpet for good..
 Instead of carpet I planned on putting on some do it yourself bed liner.
 One of the first things I did was move some of my switches that were going to be in the way. I moved my KC light switches just to the right of the key, and since I was no longer going to be running the useless factory rear light I moved the crawler light switch to this location.
 Getting that glue off was proving to be a very time consuming challenge.
 I used a grinder but that was taking all the paint off too, so I tried using some acetone. Side note whoever decided to spell it "ace-tone" instead of asatone is a moron.
 Most of the stripping is done
 The front proved to more more time consuming with all the nooks of the body mounts and seat mounts.
 I throw down a layer of primer to prevent rusting while we do the rest of the metal work.
 I was a little concerned with how well the Herculiner would stick to primer as it is intended to be put on scuffed up topcoat. So I test the stuff on the fuel pump acess pannel.
 Backside. At one point I wanted to remove all the factory rubber layer up front but after discovering how much of a pain this is to remove I decided to cover it in Herculiner.
 So I ran another "test" spot under the front foot area.
 Seats put in for mockup/motivation.
 I don't know what's more motivating, the seats or Bar Refaeli in a bikini.
 Plates used to go through the body. While these are technically "bolt on" good luck trying to get the cage off. We did this to avoid any gaping holes in the body as I still intend to use the 4runner as my tent.
 $60 at home depot gets you about 1000 sq ft of this outdoor pool liner which is cheap, black, and weather resistant.
 I debated keeping the factory headliner but wanting the most head room possible I decided to scrap it.
 However I wanted some sound deadening so I decided to use some of the pool liner as a cheap dynamat. First I made a cardboard template.
 I wanted a clean install so I ran a ton of newspaper to mask off the area. This turned out to work agaist me as when I bumped the newspaper it stuck to the rubber.
 After throwing down the first layer I spray some more glue for a second.
 Second layer down. This was definately a challenge to get in straght and flat and although I'm satisified with it so far it does have a tendency to fall in the corners. So we'll see if it lasts.
 From under the truck. You see the frame mount and bottom half of the floor brackets.
 Topside of the brackets.
 Bottom side after the tube has been welded and the bushing installed. The hope is that the bushing will still give a little and prevent too much vibration.
 Cardboard template for the aluminum sheet side pannels.
 Transfered to the material.
 I build a custom paint booth in order to get a much of the frame brackets painted as possible.
 Bumpus starts throwing some tubes while I...
 Work on trimming the aluminum sheet to fit.
 A cut and sleeve in one of the tubes.
 Using the cut and sleeve method we were able to make the tube running from the front frame mount to the rear into one piece.
 Put in place. Now since the welds were ground down you can't tell that we made this as mutiple tubes. In fact if you asked me in person I would deny everything.
 After the main tube was finished everything else just sorta fell into place. Here we are after a fresh layer of primer.
 And a first coat of black. The main tubes are from 1.50" the supports from 1.25"
 After a stinky layer of Herculiner.
 First side pannel all done, the doors fold down on a hinge and are held in place with a rubber latch.
 Both sides mounted.
 With the top on and the rear seats in.
 From the outside.
 Another shot of the side pannels. Also see the new rear seatbelts. These I took from an std cab pickup and have a much more friendly covering as me and Julie got pretty tired (and bruised) from hitting the old ones without the cover.
 With the side pannel open. I am thoroughly impressed with how well these came out.
 Front after I put all the goofy crap back in. I also took a page from the book of Guzzet and put the fire extinguisher under the passenger's feet. This will be a far more logical place than in the back on the roll bar.
 Closeup of the guzzet work that is right behind the drivers head.
 More guzzet work in the center of the over the head bar.
 So how do you make it possible for my fat ass to get in the back?
 Make the passenger seat quick release.
 Didn't even make it out of town on the first trip before the glue holding the headliner failed.

So I got over the headliner real fast.
 Without any kind of sound deading material the cab would rattle, so Bumpus found the solution. A product called Hoodliner which for about $50 will cover the entire cab in about 1" thick foam with adhesive of the back. Turned out awesome.

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