From Stock to Savage: This Toy 4Runner Build Conquers Rocks, Desert...and Daily Life

When Alex Woods picked up his 2003 Toy 4Runner back in 2012, he probably had no idea he’d turn it into the ultimate desert-rock hybrid machine we see today. After cycling through Bilsteins, Icons, and various “long travel” setups, Alex finally landed on what he calls “the ultimate setup for this platform” - and after hearing him break down his build, it’s hard to argue with that assessment.

The heart of Alex’s setup revolves around Marlin Crawler’s RCLT HD IFS kit with a +2.75" configuration, paired with Radflo coilovers and bump stops. Out back, he’s running a custom 3 link suspension with a Dana 60 and more Radflo coilovers. This combination delivers something most wheelers only dream about - a rig that can handle technical rock sections, blast through desert whoops, haul the family on camping trips, and still cruise 80 mph on the highway without wandering or shaking.

Alex makes a crucial point about front long travel that many wheelers overlook. While most folks install these kits purely for high-speed desert running, the RCLT HD setup delivers something extra - serious rock crawling capability with the added clearance and stability that comes from increased track width. Standing next to his 4Runner with one front tire high on a rock, Alex demonstrates how that the 5.5" wider stance translates to real-world confidence when you’re picking your way through technical terrain.

The install wasn’t exactly a weekend warrior project. Alex tackled the Marlin kit installation in his garage with minimal help, though he admits to being somewhere between novice and intermediate with the welder.

One thing Alex learned the hard way - those plastic fenders have got to go. The massive up-travel built into this setup means constant trimming and re-trimming. Even after installing a Radflo 2" stroke bumpstops and maximizing the shock cycle’s up-travel, he’s still kissing the fenders on full compression. That up-travel is crucial for IFS performance though, especially in rocky terrain where you need that front end working as much as possible while the solid rear axle does its thing.

The armor package stays practical with front and rear bumpers plus sliders that Alex fabricated himself. He’s running front and rear air lockers wired through factory-style OEM switches to keep the interior clean, and the whole package rolls on SCS wheels wrapped in 37" BFG KM3s. Alex says he wants to run bigger rubber but recognizes that 37s hit the sweet spot for his mixed-use approach combining desert running, rock crawling, and highway miles.

That rear suspension setup deserves special attention. After a kit he purchased didn’t really work, Alex dove deep into research and pieced together his own 3 link system using brackets from multiple manufacturers including R-Tech, Ballistic, and WFO. The 12" Rad Flow coilovers pair with an East Coast Gear Supply Dana 60 hybrid axle and an anti-rock bar to control body roll while helping the front end do more work in technical sections.

Alex can’t emphasize enough how much difference compression adjusters make on the coilovers. Being able to flip from full soft to full stiff transforms the truck’s character for different terrain types. That adjustability means you’re not stuck with one compromise setting - you can dial in exactly what each situation demands.

The truck being down during the build wasn’t easy. Four to five months without wheeling tested Alex’s patience, but the results speak for themselves. Even his bumper build happened in stages, starting with just a lower bar for body protection during his first post-build runs, then adding the outer tube and finally the swing-out tire carrier he admittedly doesn’t love but needs for cargo space.

For anyone considering the full Marlin Crawler RCLT HD treatment, Alex strongly recommends going the complicated route and cutting out the factory bump stops. The tubbing work takes time and patience, especially around the upper fender well area, but maximizing that up-travel makes all the difference. His one regret - not accounting for body mount compression during the clearancing process. He recommends leaving 3/4" clearance all around instead of his 1/4" clearance approach.

With 250,000 miles on the odometer, Alex isn’t done yet. An FJ Cruiser transfer case and Taco Box have been sitting in his garage for months, waiting for installation. The plan includes twin-sticking the FJ case for maximum flexibility and adding that ultra-low gearing that makes such a difference in technical terrain. He’s also eyeing 14" stroke rear coilovers and beefier skid plates made from quarter-inch material.

You can follow Alex’s continuing build adventures on Instagram @lostinthewoodst4r, where he keeps detailed story highlights covering the RCLT HD install, 3 link build, and bumper fabrication. For a truck that started as basic transportation, Alex’s 4Runner proves what’s possible when you combine quality components, solid fabrication skills, and the patience to do things right.