1st Generation Toyota 4Runner, Plywood Bed Side Panels

1st generation Toyota 4Runner, making replacement bed side panels.

The original factory plastic side panels are showing signs of nearly 40 years of use and abuse. A previous owner of the vehicle had made cutouts for 6" x 9" speakers in the panels. Those openings, especially the screw holes, were badly cracked. I decided to eliminate those speakers as they're in the way of a future battery cage as well as they would be covered by a future fold-down cargo deck. I'll come up with another solution for the rear speakers.

I used the more intact passenger side panel to trace an outline on a half sheet of plywood. I did have to make some minor adjustments to the plywood as it's a flat sheet compared the the molded plastic it was to replace. Both side panels are identical in overall shape. I also didn't cut out any of the openings in the panels at this time. I felt that would weaken the panels with all the fitting work they'll need. That step will be done later in an upcoming video.

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.

Hopefully

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:
https://amzn.to/469MSON

Killer Toy Tops:
https://killertoytops.com/

Some web archive links to soft top companies mentioned.
Kayline Mfg.:
https://web.archive.org/web/19990428193849/http://www.kaylinetops.com/
Specialty Top Co.:
https://web.archive.org/web/20010819040832/http://www.specialtytopco.com/
Can-Back:
https://web.archive.org/web/20010202070000/http://www.can-back.com/

#4Runner #softtop #seatback