My 02 SR5 4WD Build - "T. Belle"

I second that.

 

bump for updates

 

x's 2

 

Sorry, guys! No updates yet

One of the rear Icons blew-out a few wks ago and had to get it replaced (under warranty).

Also, been out of town for awhile and just got back today.

 

8/19/13

Finally had some free time today to work on Belle...

To better accommodate the winch power cable (and future add-ons, like auxiliary fuse block), I swapped out the old + battery lug with a Fastronix mil-spec lug.



While looking around for an easy-to-access spot to drill/mount the (provided) TJM battery disconnect switch, I realized I didn't have to drill at all.

The switch mounting plate fit snugly where the battery carry strap used to be. Two zip-ties were used to secure it onto the battery.



Battery disconnect switch ON = TJM Blue LED ON

So far, I'm really impressed with the TJM Stealth winch. It has a lot of features my FJ's SuperWinch Talon doesn't have, at almost half the price!



Now with power, I was able to add a Factor 55 ProLink thimble (slightly used for $85 on eBay!) and winch it snug to the fairlead.



For the final touch, a pair of 3/4" ARB bow shackles were installed.



Large rubber washers were added to prevent rattling. A low-cost alternative, compared to DayStar D-Ring Isolators or Crown Automotive D-Ring Isolator Bushings (http://www.quadratec.com/products/92144_1900.htm).

 

9/25/13

Yesterday, my new rear bumper was fiiiinnnally ready to be picked up. Ordered in early July, various snafus and circumstances (too many too detail) delayed completion until now.

For the rear bumper, nothing fancy needed. Just something simple (and light) to protect my rear end, with integrated 2" hitch receiver and (2) shackle points also.

As a nice finishing touch, Jason added some dimple-died aluminum filler plates on top.







2" receiver behind license plate.



While at Demello, I had the front Icons raised (~1.25") to level out the front sag. Much better now. She rides like how she used to ride before the new bumper/winch combo was installed.

 

bueno

 

9/25/13

To comply with certain traffic laws, two waterproof (IPF65) LED strips were added above the rear license plate.

 

Nice wrap around bumper and bed cage.

 

Ur roof rack is sweet. One of the cleanest firsts gens ive seen

 

Thanks for your kind words and patience, guys!

10/4/13

Goodbye, summer hell! No more ridiculous heat, which means I can start working on Belle again. Since auxiliary lighting is next on the agenda, I started on electrical/wiring today.

A dual AGU fuse block was installed on top of the engine bay fuse cover. Each circuit will protect a Blue Sea Systems 5025 fuse block - one in the engine bay, the other inside the cabin.



The BSS 5025 inside the engine bay was mounted to the wall of the AFE CAI with 3M DualLock. This block will be used for:

1. Acro 55W lights 12V & Ground
2. Ironman4x4 20" LED 12V & Ground
3. Engine bay LEDs 12V & Ground
4. Ironman4x4 LED switch 12V & Ground
5. Winch bay LED 12V & Ground
6. Spare

Acro switch 12V will be connected to Ignition 12V (in the dash fuse panel)



I didn't have time to complete the Ground. The Ground and BSS 5025 #2 will have to wait until this wkend. I finished the day with some NoLoss captive valve caps on my tires.

 

10/5/13

My order of Rigid Duallys arrived. These will eventually go on top (rear) of the roof rack.



The single diffused LED will double as a bed light and amber dust light (with the amber cover), and will be on a separate switch/circuit from the two flood LEDs.

In the meantime, I also ordered an Ironman4x4 20" LED from trdparts4u.com. Their current free shipping sale greatly influenced my decision to buy now, rather than later.


Image courtesy of Ironman4x4

60W Spot beam, with an output of 5400 lumens. I thought about another double-row LED to match my rooftop LED, but wanted something more low-profile for the top of the front bumper.

My original plan was to go with a pair of HIDs, but the cost for a good pair was ultimately a deciding factor in going with LED. I suppose I could just forego more light(s) and save some $$, but the top of the bumper looks naked without anything.

 

Long time no hear how have you been

 

Haha what's up, Robert? Yeah, long time indeed.

Same crap here, different day. Busy now, just trying to get this truck ready for camping/shooting season.

 

Nice

 

Beautiful Truck! Extremely Jelly!

 

Thanks, travis9287!

10/5/13

The Ground for yesterday's BSS 5025 was completed/connected today. BSS 5025 #1 is now live and ready to use.




With the remaining circuit on the dual AGU fuse block, 8 AWG wire was connected and routed through the driver-side firewall grommet to the passenger-side kick panel...

(60A AGU fuses in each slot)



...where the second Blue Sea Systems 5025 fuse block was mounted with 3M DualLock. This block will be used for:

1. 42" ELS Atlas LED 12V & Ground
2. Rigid Dually flood LEDs 12V & Ground
3. Rigid Dually diffused LED 12V & Ground
4. ELS Atlas LED switch 12V & Ground
5. Amp 12V & Ground
6. Spare



BSS 5025 #2 is now live and ready to use.

 

10/6/13

Ever since the new rear bumper, I can't help but notice the large void where the OEM tow hitch and spare tire used to be. I figured some new reverse LEDs would work great back there.

Initially, I was going to find some 1.5" tube light mounts and mount them to the bumper. But, the some mounting points for lights were already underneath the bed, complete with M6x1.0 threaded holes.

Perfect for these 2" LED cubes (from superbrightLEDs.com) that I had leftover from another project. 10W Flood beam, with an output of 750 lumens each.



Mounted underneath the bed.

Each LED is powered by their corresponding reverse light. 24" pigtails were spliced into the wiring at each tail light.



In the midst of this project, I realized I hadn't yet swapped the OEM tow hitch wiring extension over from the OEM tow hitch sitting on my garage floor.

Extension now re-connected to converter and zip-tied to new bumper.



Reverse LEDs off. You can hardly notice them at all.



Reverse LEDs on.



Much brighter than the OEM reverse lights.



With so much room behind the bumper, I may go with a larger LED in the future. Perhaps a 15" or 20" single-row, we'll see...

 

10/9/13

With impending rain this afternoon, I had just enough time to install a Comet SBB5 dual band antenna and 3D5MB coax cable for my handheld Yaesu FT-60.



The hole on the weld-on antenna tab was too small to fit the coax MLJ connector, so I had to open it up with my drill/step bit. Metal shavings were easily cleaned out of the bed afterward with a welding magnet.

The new hole was then painted to prevent rust.



To protect the coax to exposure from outside elements, Raychem DR-25 sleeving and marine heat-shrink were heat shrunk over the section that will remain outside the cab (~44").



MLJ connector installed (with "When Not in Use" protective cap on).



Coax routed through rubber grommet into the rear of cab (driver-side). Drip loop to help prevent water from dripping into the cab through the grommet.




Coax routed to center console via rear/side trim and driver seat.



Comet HS05 antenna adapter.



Coax storage area (in between center console and driver seat).



Comet antenna installed.



Unfortunately, Demello made a slight miscalculation with the location of the antenna tab(s). Due to the inward taper of the rack, the antenna makes contact with the tubing.



In hindsight, tab(s) should've been 1-2" closer to the tire carrier to account for the taper. Oh well, short of re-locating the tab(s), there's not much that can be done about it now. I'll probably just zip-tie the antenna down at the point of contact, to prevent rattling against the rack.

For the time being, not really a big deal since it'll remain off while not in use anyhow (to prevent theft/damage).

 

10/12/13

I've been wanting to upgrade the ancient factory CD/cassette unit for awhile now, so I took advantage of Crutchfield's current sale on Alpines and ordered an inexpensive single-DIN CD/USB/Bluetooth receiver (with free 8GB Alpine USB drive) a few days ago.

Alpine CDE-143BT with OEM radio brackets and (provided) single-DIN receiver pocket installed. Crutchfield also provided a 1st gen Taco wiring adapter which I spliced onto the Alpine wiring harness.



Overall, a very easy install and huge improvement in sound and functionality. Now I just need to swap out the rear speakers and add a small sub to finish the system.

Definitely worth $130 and 1hr of my time. And with the receiver pocket (and non-slip foam), I now have the perfect spot for my phone (with room to spare).



The free Alpine 8GB USB drive is pretty cool. The top twists to extend/retract the USB connector.



Rigid Duallys were installed onto the roof rack also. I needed them in place to determine the lengths of wiring harnesses I'll need to build.



With dust and amber covers on.



Wiring harnesses are almost done, but ran out of sleeving to finish. To be continued later (when my order for more Raychem DR-25 arrives).