1st generation Toyota 4Runner, making replacement bed side panels, adding the original access hatch and improving the deck light switch setup.
The original factory plastic side panels are showing signs of nearly 40 years of use and abuse. I had originally traced the inside opening for the access hatches from the plastic panel. However, the plastic had a molded recess for the hatch to fit into. To recreate that in plywood, I cut the opening the full size of the hatch, sliding that opening as far forward as possible. Then I doubled up the thickness with strips of plywood glued and stapled to the back of the main panel to form a recess the thickness of the plywood and to strengthen plywood around the opening.
I was able to add a hole for an extra mounting bolt in the lower back corner, where the original plastic panels had broken. I'll be drilling out an existing hole in the bed sheet metal and fitting a 1/4-20 threaded insert. This insert as well as the one on the other side of the hatch are set back from the plane of the bed side, so required additional pieces of wood added to make the side panel sit flat. The original plastic panels were flexible enough to conform to those offsets.
A 3D printed housing for the factory deck light was designed and printed. This eliminated the need for a complicated cutout to fit the deck light back into the plywood, plus it lets the light be installed up higher on the bed side where it'll be more usable as well as above the future cargo deck I'll be adding:
3D part model:
www.thingiverse.com/thing:6654621
One thing that had to go was the carpet over the rear wheel wells. That could be retained, but the curve in the plywood would need to be cut higher to fit the carper underneath. As the carpet was going to interfere with my house battery cage, eliminating the carpet was the best choice. The tar tape that adhered the carpet to the wheel well was scraped off and the residue remove with turpentine. Multiple coats of Herculiner was sprayed onto the bare sheet metal for protection.
Materials used:
1/4" plywood cut to match the factory bed side panels.
1/4" - 20 threaded inserts and screws to replace the factory plastic push pins.
Bed liner spray, needed 1 - 15 oz. can to apply 4 coats to the 2 wheel wells:
amzn.to/469MSON
Killer Toy Tops:
killertoytops.com/
#4Runner #bedside
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