BigMike’s Big Journey: New 2016 Tacoma

It's gonna take some time guys to get version 2.0 developed which will be what our production kit will be based on, but here's to a bright future for Rock Crawling the late model Toyota IFS system!







The common failure point is in the center where both the bending stresses are the highest and the factory tie rod is the weakest. Not only have we greatly increased the size, but we're also covering more than half the distance with our very strong Mini Marlink -- which itself is only 1mm smaller than my freak'n RCV axle shafts for crying out loud!! This is incredibly great guys: I've increased strength of the weakest point by 2.4-times AND I've moved the weakest point away from the center where the stresses are the highest. COME AWN NOW!! We're also accomplishing all this without using a bolted heim at the inner joint, so there is no finicky tie rod installation/orientation issue and no fear of a bolt or nut shredding tie rod boots.





SERIOUSLY CAN'T WAIT TO TEST THIS PUPPY OUT!!!!

 

To quickly comment on the boot issue, Rocky and Tim noticed how RCV ships the shafts with the boot quite stretched; They install the inner/smaller clamp of the boot quite far up the axle shaft. You'll notice in my above pictures that when I replaced both outer boots I have left the inner clamp off for testing. Currently the boot is scrunched together about 50% more than how RCV shipped it to me. So far so good, however I only have about a tank of fuel on them. I will scrunch them up as much as I can and add clamps before I leave for Texas next week.

While proof reading, I thought of another marketing slogan: "My tie rods have bigger nuts than yours" hahah

 

April 24, 2018: Got the truck Aligned: Drives PERFECT

I forgot to include this but beings it's MarRack related now would be the best time to post that I got the truck aligned last Tuesday and it drives 100% like normal. I can hit any bump in the road while driving with one knee and the truck continues straight ahead. Driving 70 MPH on the highway also with one knee, everything feels back to normal! Steering wheel center-to-lock is about 1.7 turns which is better for Rock Crawling than the factory's 1.5, and also helps reduce stress at the already stronger rack by, what, almost 15%? Ohh man how much more good news do we need for this! The steering resistance of the 40s has gone down for sure. It feels like they are 37s again while cornering. The alignment shop got everything set to factory spec and hot damn the front suspension and steering is 1,000% ready to drive to Texas in just 3 days from today!!

 

Looks fantastic!

But now might be a good time to think about reinforcing the Lower Control Arm Mounts while you're ahead of things..
https://www.tacomaworld.com/threads/long-travel-bs-thread.109317/page-3690#post-17693396

 

Thanks man!! Thank you for this also. I found your thread last week and have a few solutions for it but no time to work on it until sometime late May.

 

Insane. The truck is awesome in so many ways.....and it was just like mine when it started.
I just want stage 1.......Congrats man. Comin along epic......

 

Awesome work on the steering mike!

There’s a guy who already made hubs work on 2nd gen and 3rd gen tacos. Here’s the link, uses factory parts.

https://www.tacomaworld.com/threads/free-wheel-hub-conversion-3rd-gen.513930/

 

What are the benefits of the free wheel hubs vs. what we have now?

 

For the new rack you had to move the tierod/spindle connection out and down. You mention it''s higher but it doesn't look it. Will new or modified spindles be needed in your updated kit you mention? That'll add quite a bit to cost.

What size rims are you running and how close is the tie rod end to the rim?

What, if any, stress does the angle of your tie rods put on the steering rack itself? Any extra wear?
How is your OEM pump handling the new rack? When installing a new rack and fluid, what's the best way to get the bubbles out of the fluid?

 

Thanks PB FAB. Regarding the kit you linked to, I have seen the kit in person and I don't want to knock it because it's great that it exists, but because it uses outer CVs that are weaker than stock, it should not be used for Rock Crawling. This is a good thing. It means there is still a serious need for a strong kit. *wink* *wink*

Main benefit is to lower rolling resistance = better fuel economy. Other benefits are that all components that were previously constantly spinning will now last far longer (CVs, boots, front differential bearings and side gears). Drawback is that you'll lose the ability to engage 4WD on the fly and will instead have to come to a stop to get out and lock each hub plus remembering to unlocking them when you no longer need 4WD.

@Mike330R Thank you for the excellent questions

Please bear in mind that my goal is to push the IFS system further into the realm of Rock Crawling. Current limitations of the IFS system, including kits already in the aftermarket, leave far too much to be desired and I believe we can make a dent at the argument of "IFS sucks; Just SAS it". The MarRack is only the start and as an R&D project I must release info only when appropriate. I've alluded to this on multiple posts and will expound more here: In it's current state the MarRack has already remedied at least one absolutely critical Rock Crawling issue when comparing a Solid Axle Swap to IFS, and as a hint, it's not related to steering. Much more info will be coming late summer.

Another excellent question, I was anticipating this and already have the following response prepared:

In case any TRD Off Road or other owners with 16" wheels are curious about TRE to wheel clearance, as we should expect this to be the majority of those looking to go Rock Crawling, prototype v2 will utilize the "incredibly unique approach" mentioned in reply #556 which I am estimating will clear 16" wheels

To answer your first question, my TRD Sport came with 17" and I decided to stay with the original wheel size.

There will be extra stress and wear due to the required tie rod angle. Fortunately both the tie rods and MarRack are larger and stronger than stock. The angle will be reduced in my second version, however, not only will it be impossible to return the angle to factory, but this is a key element of my intended design that will be highly desirable soon. This is related to the "blowing of minds" I referred to in the same reply above.

So far so good! I not only have close to 1,000 miles on the MarRack, but I also have 4 hours of decent Rock Crawling abuse on the system with my 40" tires aired down to 4 PSI and I never once had the steering loose power due to heat or stress. It is definitely easier to turn the steering wheel now with 40s + MarRack than it was with 37s + stock rack. I'll be posting details about this wheeling experience as soon as I can get caught up here

I followed the factory Tacoma procedure which was pretty simple: Add fluid, slowly turn wheel back and forth until fluid level stops going down, fire up the engine, hold wheel at both full locks for 3 secs, turn engine off, repeat. I've attached a PDF for reference

 

A few weeks ago I received a message about our awesome Toyota shop wall logo so I figured I'd show it off lighted

Marlin bought the sign back in the 1990s from a TLCA Toys-4-Fun club member who got it from a Toyota dealership that moved and no longer needed it.

We've had it ever since!

 

Guys, I'm running out of time and need to get updates posted so I hope you don't mind me breezing through some replies a bit. Feel free to ask any questions and please don't get too much drool on your keyboards!

April 15-26, 2018: Finally made my Tacoma dreams come true

During much of the above I was simultaneously working on the two things I missed the most my entire time while wheel'n the Tacoma

Hmmmmmm......





This looks very good

 

Hmmmmmm......







Oh yeah, this will do nicely, no problem

 

Hmmmmmmmmmmmmmmm..........



Whoops, was that not supposed to fall out?



Perfectly measured just before the body crossmember!

 

Just another day in the office, doing another World's First on a Tacoma....



Yes, that is our famous MC08 Double-row Maximum Capacity Bearing Dual Case Unit!!



Which means! You guessed it! TRIPLES! I believe I'm the first 2005 and newer Tacoma to do this and all I can say to myself is "It's about BLOODY TIME MIKE!!"



The MC08 Unit: 2.28:1
The (existing) TacoBox unit: 4.70:1
The Transfer Case 2.57:1

I now have an 8-speed Transfer Case system comprising the following gear ratios:
1.00 (High Range - High Range - High Range)
2.28 (L - H - H)
4.70 (H - L - H)
2.57 (H - H - L)
5.86 (L - H - L)
10.72 (L - L - H)
12.08 (H - L - L)
27.54 (Low Range - Low Range - Low Range)

Yes. I now have a 28:1 transfer case.

 

Performing last remaining trimming work...







Look at that! Tis a thing of absolute beauty! Like it was meant to be there! Thank you Access Cab!

 

Ok, let's see here...







Hmmmmmmmm...... Ok if we remove this thingy.....



Eggcellent

 

/me whistles while he works







Huh. That was easy.



Turning out SO much better than I originally planned!

 

Whip up dual cable holders, sure no problem...







Looks good so far