Here we have a 2004 Tacoma Double cab. It was wrecked when it rear ended a tow truck that had the rear forks out. One of the forks went into the passenger side of the grill just above the frame line. It took out everything above the frame on the passenger side and ended up pushing back the firewall a few inches. For the most part, the cab is straight minus the firewall. So, the truck is salvageable. It also hit the power steering pump and broke it out of the head. Amazingly, the motor still runs.
So, here is the plan. I plan to pull the motor, tranny, Tcase, etc this weekend. I will tear down the heads. I have a core 96' motor that I will rob the heads off of and take them to a local engine shop to me to have them machine & rebuild the heads.
While that is going on, its going to the Carriage Shoppe here in Ft. Collins to see of they can pull back the cab to straighten it out as much as possible so I can get a windshield back into the frame. After this is done, I will either tube out the whole front end and hang new fenders, hood, grill, etc off of it. Or, if they can get it straight enough, I will weld back in new inner fender supports, radiator core support, etc.
The build plan is simple. SAS using TG's kit "C", but modify it just like I did in the "Frenchy" build by frenching everything into the frame. However, I will be using a Diamond axle up front to allow me to keep the caster in spec. This way I can rotate the knuckle balls after install before welding as well as weld in the spring perches myself. It will get a HP 3rd with ARB and 5.29s.
I am sticking with leafs in this build using the KISS principle. After all replacing a $2 spring bushing is a lot cheaper than replacing a $80 heim joint.
Here is the truck the day I bought it
FWIW, I really have no real time table for this build. I will do it on weekends when I am not working on finishing my buggy or after hours only so it doesn't effect what is going on in the shop.