1301 4wd 11 Synergy Suspension Baja Basket Mount Bar - Photo 41842822

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Getting the spacing right on the front crossbar was trickier, as the tabs went on the underside of the tube and couldn’t be reached for tack welding. I needed a template and made one by measuring the bolt spacing and then drilling two carefully measured holes into a piece of mild steel flat bar.

1301 4wd 01 synergy suspension baja basket design

This represents the least amount of tools and gear I usually roll with. It’s good to be prepared, but it’s possible to overdo it. On top of that, this arrangement makes it hard to access things when they’re needed. Fortunately, our stuffed snake mascot doesn’t add much weight.

The small Baja Basket measures 33 by 24 inches. Note the dimple-died construction, a manufacturing process that cuts weight and adds strength all in one fell swoop.

The top rail provides multiple places to lace lashing straps through. Several pre-punched holes open up mounting options.

The medium Baja Basket measures 42 by 26 inches. There are no plans to weld to the medium Basket, so the powdercoat finish was the classy, no-hassle choice.

We’ll be building a two-tier mounting system for the 4Runner’s cargo bay. Synergy Suspension’s product line includes a wide selection of pre-cut fabrication tabs. These particular tabs are perfect for using hooked-end ratchet straps. They’ll be welded to the base of the Basket mount to allow ratchet-strap use when needed.

Urethane bushing mounts can fill several fabrication needs. In this case, they’ll provide a degree of flex between the 4Runner’s sheetmetal floor and the tubing structure that holds the Baja Baskets.

Plan A was to keep the spare tire in the back and mount the small Baja Basket above it. The medium Basket would’ve been installed in place of the second-row seats when the seats weren’t needed for passengers.

Further into the brainstorm, I realized that swapping out the second-row seats is a major hassle, and I’d like to be ready anytime to carry extra passengers. The spare tire is getting an eviction notice and will soon reside on an external tire carrier. The Baja Baskets will enjoy a two-tiered mounting arrangement. The Powertank and the fire extinguisher will be easy to get to.

The two-tiered Basket mount will tie into the 4Runner’s existing D-ring floor mounts. The Synergy bushing mounts will be used for the rearmost crossbar. The urethane has to be removed from the sleeve for welding. If not, you’ll cook the urethane.

The new mount ties into the factory D-ring location. The factory bolt looks small and is small. However, it’s held my spare and other heavy cargo reliably in place for several years now, so I trust it. If and when I install a rollcage or internal rear shock hoop, I will tie the Baja Basket mount into that for added strength and peace of mind.

Pre-stamped tabs and a length of round tubing will complete the rearmost crossbar.

My welding torch and foot pedal were long enough to reach the 4Runner without moving the welding machine. The ground clamp was too short, so I used jumper cables to make up the needed distance.

Getting the spacing right on the front crossbar was trickier, as the tabs went on the underside of the tube and couldn’t be reached for tack welding. I needed a template and made one by measuring the bolt spacing and then drilling two carefully measured holes into a piece of mild steel flat bar.

I drilled a third hole into the template so I could use my Van Sant tab and bracket holder to position the tabs and the template.

The effort paid off, as the tabs on the forward-most crossbar bolted perfectly into the factory D-ring holes. The front crossbar is solidly mounted. I think one set of urethane bushings will provide sufficient flex between the tubular Baja Basket mount and the sheetmetal floor. This won’t be a three-part (or more) story. We’ll finish this up next time so we can start enjoying the Baja Baskets.