Igor: Double Cab 4x4. Frankenstein's Helper

Up to you. I don't really sleep in so whatever works for you.

 

Haha okay. I'll make the trip this Saturday!

@SconnieHailer gonna be around to join? Or still in Wisconsin?

 

Fawk! Great week to be told I'm maybe working Saturday lol. Poor planning on someone else's part is not in my favor this week. I'll be working on an I-25 interchange all week near Loveland. I'll hope to be home Sat but who knows. Be home Sunday for sure.

 

Well. Ripping out ac may take a while and brake lines..haha

Could still be there find you.

 

Update time!

Ive had these parts for about 3 months now and it seemed like it was time to get them in. I installed a Bussman Relay box and some ditch lights. Gonna try and do a write up as usual but may be missing photos. Oh well.

This being the 2nd tacoma build and the thousandth time ive done wiring on a tacoma. I REALLY wanted to do it 100% right and be super clean. So I went all out on this.

I did very little if not any fab work of my own. Bought stuff from places mostly. Was expensive compared to how i usually operate, but worth it I think. Here is my list of components I purchased.

• Bussman Relay box built by @Roo1041. He did a great job on this box. Few small things that would make installing in a 1st gen a bit better but he followed this write up( https://www.tacomaworld.com/threads/diy-build-and-install-a-bussmann-rtmr-fuse-relay-block.399454/ ) on how to make one and did it splendidly. Not only that but he also included all the parts for me to build harnesses off the relays and fused ends. The way this unit is wired, it has 5 relayed circuits and 5 fused ones for a total of 10. You can contact @Roo1041 if he still is making them. Price was good too.
• Paranoid Fab Bussman mounting bracket - http://www.paranoidfabrications.com/shop/1st-gen-tacoma-bussmann-relay-holder/ This was nice to use on my 2003, cant use one on Frankenstein due to the EVAP crap.
• Paranoid Fab switch Bracket - http://www.paranoidfabrications.com/shop/1st-gen-tacoma-din-switch-plate-6-switch-holes/ VERY nice unit.
• Some switch blanks - http://www.paranoidfabrications.com/shop/carling-switch-blank-plug/
• CBI Offroad Ditch Light Brackets & Carling Switch- http://www.cbioffroadfab.com/produc...-products/1stgen-tacoma-ditch-light-brackets/ I did the add on for the switch too. Didn't make sense to order another switch from somewhere else. In check out it let me add custom text too. I had "Ditch Lights" engraved on it. Plus free Tshirt!
• 40w 5'' LED pods - http://www.ebay.com/itm/281957156679?_trksid=p2055119.m1438.l2649&ssPageName=STRK:MEBIDX:IT Suckers are bright as fuck
• Ground bus Bars -
  $15 Blue Sea Systems 2304 100 Amp Mini BusBar with 5 screws, One size, Without Cover, Black
  https://www.amazon.com/Blue-Sea-Sys...d=1432950481&sr=8-11&keywords=blue+sea+busbar
• Some 2 pair wire from Ace about 10'
• Fuse tap from autoparts store
• 100amp circuit breaker
• 15' of 3/8 wire loom
• Ended up needing like 5'' of red 18ga and black 18ga wire
• Basic tools and wiring tools

On too the photos. Sorry I skipped some as some things are obvious or ive covered it in my other build thread.

The bussman unit looks great and is made just like in the writeup which was helpful to refer to on how it was wired.

Thread is here: https://www.tacomaworld.com/threads/diy-build-and-install-a-bussmann-rtmr-fuse-relay-block.399454/

BussmanDitchlights-4.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-5.jpg by Monte Nickles Photos, on Flickr

Riley even labeled the outputs.

This is for Fused Relay

BussmanDitchlights-8.jpg by Monte Nickles Photos, on Flickr

and just fused

BussmanDitchlights-9.jpg by Monte Nickles Photos, on Flickr

The round yellow terminals are all grounds while the multi pinned plug is for the switch harness.

The Paranoid Fab stuff was great too. I ended up scuffing up the face of the switch panel and putting about 5 coats of black paint on it. I didn't paint the bussman bracket, they are aluminum so won't rust and didn't want to bother with it.

Cool logo

BussmanDitchlights-2.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-3.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-6.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-7.jpg by Monte Nickles Photos, on Flickr

Spare circuit breaker we had lying around. The Bussman box i guess is only rated for 80 amps though. Oh well.

BussmanDitchlights-10.jpg by Monte Nickles Photos, on Flickr

This was the only "major" problem i found with the bussman box Riley made. He had not only crimped all the ends, but had soldered them. On this connector he used a bit too much and it flowed up to the tip which means the male pins couldn't slide in. I was able to break it loose though with a small screw driver. He took the problem well and learned something and I didn't mind.

BussmanDitchlights-11.jpg by Monte Nickles Photos, on Flickr

If you go through the whole writeup on how to make a Bussman, you see he bolts two ground buses to the outside of the Bussman box. Well the Paranoid bracket for us 1st gens doesn't have the room.

But i noticed the buss bars mounting holes are pretty much identical. So i figured i could mount them on the same spots.

But the Bus bars holes are bigger so i just decided to step up to a 1/4'' bolt. That meant pressing the brass fittings out of the bussman.

BussmanDitchlights-12.jpg by Monte Nickles Photos, on Flickr

Had to drill out the bussman a bit and the bracket

BussmanDitchlights-13.jpg by Monte Nickles Photos, on Flickr

These are the bus bars.

BussmanDitchlights-14.jpg by Monte Nickles Photos, on Flickr

Now im not a big fan this wiring setup because that means i have to ground everything right here AND i have to run power and ground wire to my accessories. But, whatever. It turns out good.

Went and got some 1/4''x1'' bolts and nuts. Should have gotten 1/4''x3/4'' though. But everything lined up and fit.

BussmanDitchlights-15.jpg by Monte Nickles Photos, on Flickr

Then i ran the ground wires across to the opposite sides. Would have been much nicer if the wires could have gone to the same side but the wires where just a touch short for that to make the angles work.

BussmanDitchlights-16.jpg by Monte Nickles Photos, on Flickr

Drilled two holes for the relay and cut up and crimped up some 4ga wire for power and ground.

Came out nice.

BussmanDitchlights-32.jpg by Monte Nickles Photos, on Flickr

You can barely see it but i have a small chunk of 4ga running from ground bus 1 to the bus 2

BussmanDitchlights-33.jpg by Monte Nickles Photos, on Flickr

And here are the parts for the output harnesses. I used some 2 pair wire and made a nice harness for my LED pods and put the connector on the other side.

BussmanDitchlights-17.jpg by Monte Nickles Photos, on Flickr

Now for the LED install and brackets. I won't go into major detail on these as i did with Frankenstein. But i do want to show how to do part of it as these fenders are much different. The 01-04 front fenders are a bitch to totally take off, i guess. So the easiest thing is to just pull the top part up.

Take the three bolts on top of the fender out.

BussmanDitchlights-20.jpg by Monte Nickles Photos, on Flickr

And then this guy inside of the door

BussmanDitchlights-21.jpg by Monte Nickles Photos, on Flickr

Then grab the fender a pull up, it works well to wedge something under the lip about where the middle bolt is to hold up the fender. I used a screwdriver.

BussmanDitchlights-22.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-23.jpg by Monte Nickles Photos, on Flickr

Should be able to access the two hood bolts nowwith a ratchet and 3'' extension and shallow 12mm socket.

BussmanDitchlights-24.jpg by Monte Nickles Photos, on Flickr

Then its pretty simple. Undo the bolts, set the brackets on, start trimming the cowling till the bracket fits. Then use the CBI supplied bolts and bolt it up.

Don't put the fender back yet, you'll want it open to get the wiring harness out.

I ran the harness through these holes into the fender well and the pulled it up to the top. There is a hole on each side in the exact same spot.

BussmanDitchlights-5.jpg by Monte Nickles Photos, on Flickr


To help pull the harness up to the top i came up with kind of a cool trick. Otherwise its a major PITA with the fender skirt still in.

Get some magnets, we have a stack of small super powerful earth magnets, some electrical tape, and a magnetic extension rod.

BussmanDitchlights-25.jpg by Monte Nickles Photos, on Flickr

Tape the magnets to the end of the wire harness

BussmanDitchlights-26.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-27.jpg by Monte Nickles Photos, on Flickr

Waalaa!

BussmanDitchlights-28.jpg by Monte Nickles Photos, on Flickr


However....they are magnets...and the fender is..steel...but with just a little bit of fanageling, a hell of a lot less then without the magnets, you'll get it attached. I put the extension magnet in from the door side.

BussmanDitchlights-29.jpg by Monte Nickles Photos, on Flickr

Plus then it holds the harness while i get the lights

BussmanDitchlights-30.jpg by Monte Nickles Photos, on Flickr

Then i bolted the lights on. They mount nicely with a cool and simple mounting setup. However the bolt is super super small compared to the hole the CBI brackets are drilled for. So i used two stainless fender washers and all was well.

BussmanDitchlights-6.jpg by Monte Nickles Photos, on Flickr

I like the lights.

BussmanDitchlights-2.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights.jpg by Monte Nickles Photos, on Flickr

Here is a shot of the trimmed cowling.

BussmanDitchlights-3.jpg by Monte Nickles Photos, on Flickr

I have lots more photos on the install of these brackets in Frankensteins build thread if you are interested found here: https://www.tacomaworld.com/threads...rail-rig-and-bs.159436/page-535#post-10417256

Just becareful, that link is a huge build update and tons of hi res photos. The CBI photos are about 3/4 of the way through the post.

Connected up the harness and pulled back the slack into the fender but left the quick release within reach. Then bolted up the fender again.

Cut a slit into the stock grommet on the driver side and pushed the molex end of the switch harness through. Pulled it all the way through till the three other wires came through.

BussmanDitchlights-31.jpg by Monte Nickles Photos, on Flickr

Then its time to remove the dash a bit.

This is a good video to show how to do a 01-04 center section.

https://youtu.be/9pAGomsyUHA?t=3m30s

Its the same as my 1996 except for this lil bastard behind the ashtray.

BussmanDitchlights-34.jpg by Monte Nickles Photos, on Flickr

Then it just pops off.

BussmanDitchlights-35.jpg by Monte Nickles Photos, on Flickr

Also helps to remove the cover under the steering wheel. Just 4 10mm bolts and one screw. then you can pop the clock out too.

Then its time to hook up wires. I started with the single wire coming out of the harness. This is the power wire for light that turns on when you flip the switch on and provides the power for the coil side of the relays. I used a simple fuse tap for this.

BussmanDitchlights-45.jpg by Monte Nickles Photos, on Flickr

I tapped into ECU-B fuse because it has constant power. That way I can turn the lights on without have the ignition on.

BussmanDitchlights-46.jpg by Monte Nickles Photos, on Flickr

I can the main switch harness and the two pair wires up under the steering column with the stock harness.

BussmanDitchlights-37.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-38.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-39.jpg by Monte Nickles Photos, on Flickr

The two pair wires stop right at the clock, which at first i though was perfect but ended up not being, ill explain that later. I kept running the main switch harness to the center. Its like the little cut was made for it.

BussmanDitchlights-40.jpg by Monte Nickles Photos, on Flickr

You could say i had some..slack

BussmanDitchlights-41.jpg by Monte Nickles Photos, on Flickr

Not bad though. Probably could have run it into the headliner if i had an over head switch panel.

Luckily the PO wasn't an asshat and the stereo install was very clean and there wasn't a rats next of wires. Which meant there was plenty of room for the spare wire.

BussmanDitchlights-42.jpg by Monte Nickles Photos, on Flickr

I just looped it up and zip tied it up.

BussmanDitchlights-44.jpg by Monte Nickles Photos, on Flickr

Attached the switchback end of the harness and was done with that.

BussmanDitchlights-43.jpg by Monte Nickles Photos, on Flickr

Next was wiring up the two pair wire i had left. This is a ground and power wire that is also for the switches. Its for the independent light though that lights up the lettering of the switch. I wanted for it to be dimmable with the stock interior lights. I thought the clock would be perfect but thats where i fucked up. But im going to show this anyways as its when i took photos of splicing the wires.

But DON'T DO THIS. I'll show you the right place to splice in a bit.

I thought this would work because of the back of the clock

BussmanDitchlights.jpg by Monte Nickles Photos, on Flickr

I saw ILL which means Illumination and figured that had to be there....shoulda tested with a volt meter first.

Anyways i was too stoked on how the wires where the perfect length and went for it.

BussmanDitchlights-36.jpg by Monte Nickles Photos, on Flickr

Stripped the end of the wire and also a section out of the stock wire.

BussmanDitchlights-47.jpg by Monte Nickles Photos, on Flickr

Used a small screwdriver to split the stock wire to make an eyelet.

BussmanDitchlights-48.jpg by Monte Nickles Photos, on Flickr

Then put the other wire end into the eyelet and twist it to wrap around.

BussmanDitchlights-49.jpg by Monte Nickles Photos, on Flickr
BussmanDitchlights-50.jpg by Monte Nickles Photos, on Flickr

Do to the other wire

BussmanDitchlights-51.jpg by Monte Nickles Photos, on Flickr

i added a bit of solder

BussmanDitchlights-52.jpg by Monte Nickles Photos, on Flickr

Used some electrical tape

BussmanDitchlights-53.jpg by Monte Nickles Photos, on Flickr

Then realized i fucked up.

The clock doesn't dim

But the emergency flasher button does. And is right above. But the wires are still too short. So i had to extend them just a bit.

Tested with a volt meter this time

BussmanDitchlights-54.jpg by Monte Nickles Photos, on Flickr

Did the same thing just with spare wire.

BussmanDitchlights-55.jpg by Monte Nickles Photos, on Flickr

Then buttoned it up for a super clean look.

BussmanDitchlights-59.jpg by Monte Nickles Photos, on Flickr

The just had to connect all the quick plugs and the 4ga wire and install the bussman.

BussmanDitchlights-4.jpg by Monte Nickles Photos, on Flickr

Cleanest install ive ever done for lights and wiring.


But who cares. Output shots!


So this is what i did. I didn't have my tripod with me so they aren't exactly the same. But i basically adjusted my camera settings so that the picture with my low beams on reflected close to what i saw with my eyes. then i just used the same settings for each photo.

I did NOT edit these photos, they are 100% raw and i did not change the camera settings for any of the photos.

Low beams.

BussmanDitchlights-56.jpg by Monte Nickles Photos, on Flickr

High Beams

BussmanDitchlights-57.jpg by Monte Nickles Photos, on Flickr

High beams and 40w pods.

BussmanDitchlights-58.jpg by Monte Nickles Photos, on Flickr

Pretty happy with them and even happier with the install.

Hope that was helpful to some.


Next mod, brake system overhaul!

 

What size lugs did you use for the circuit breaker?

 

1/4"x 3/4 I believe. 1" long would haven been bette

 

I got that same breaker for my battery but all the have is 3/8" hole lugs. Damn

 

Idk. Maybe they were 3/8s. I can't remember. Just take it to the store and get some stainless bolts that fit haha

 

Wait what. I was talking about the lugs to attach the cable to the studs on the breaker hahaha

 

ohhhhh ha

yea okay. I had to use 3/8s too. The lock washer holds it down fine.

 

Awesome thanks!

Keep modding it then I'll trade you

 

I'll think about it haha

 

Just watch in a year you are gonna have two long travel expo rigs

 

oh god haha







probably...



I like the front LT too much.

If Front Range Offroad release's its custom +2 kit that would be hard to pass up i think.

 

So I got some wheelers super bumps to install. The front is going to take some custom tweaking. I ordered some UHMW a 3.25"x 1'

It's well known the super bumps work great but aren't designed for 1st gens. So to make mine work I thought I could cut the bottom down at an angle. But that can't work since Id be cutting off the part that the bolt holds down the bump. So to cope I'm goin to make angled spacers and then cut then tops down.

 

Curious to see what you come up with and how it works out.

 

I have an idea. Hope it works. Figured you'd be interested after our last chat about them.

 

Should work but make sure you have a way to keep the angle block from spinning.

 

Good point. Spider washer may work.