Z's Approach/Utility Build

Exhaust Chop - Cut - Trim

Here's the original post, copied here.

Decided to get this done this weekend as I am tired of driving around with the spare rattling around in the trunk. (No pun intended) After taking a look under the truck, i decided it would be easier to just pop the rear exhaust section out and cut and re-weld in the shop. Plus, it's kind of nasty out at the moment and my shop is warm...

If i did this again, I'd consider buying a couple replacement bolts and the exhaust gasket for reassembly. I almost didn't get the bolts out - they were super stuck. Even with penetrating grease, one of the bolts started bending. But, a bit of tapping and whacking and they both finally loosened. Next I squirted the rubber thingies with some soapy water and pried them off. Kind of a pain in the butt. A channel lock was pretty useful for pushing them over the barb.

Into the garage.



I marked where I wanted to cut when everything was still on the truck. The abrasive saw is perfect for this.



Next, cut off a bent section from the end of the tail pipe I'd just cut off. Also, thought the little heat shield might come in handy, so I popped it off for later. Then lined everything up and tacked the bent bit on. The tailpipes were very not-round so all the clamps are to try to get the two very not-round pieces to sort of line up.



Back on the truck for a quick test fit, then back in the garage for welding and some weld-clean up. I wish I still had a TIG setup. I'm not so good making pretty welds with the MIG.



Got it back installed with the old gasket and old bolts...



Test fit the spare and at least the tailpipe bracket isn't interfering! Just need to work on the spare carrier. Will save that for a sunny day.



This only took a couple hours!

 

Dash/Stereo Bay/Contura Switch Integration...



This project has been in the making for months, now - I can hardly believe it's done, and how long i've spent working on it. The original idea is that I wanted to mount an aftermarket stereo, a wad of Contura switches, the factory hazards and indicators, and an iPad where the stock stereo goes. I'd looked at a couple single and double din aftermarket panels, and didn't think i could integrate the iPad and conturas in a way that would make me totally happy. I wanted something like this:


But, the hole and mounting features are a collection of curvy surfaces, angled holes and press fittings that are not meant to be replicated in metal.


Whatever... I thought I'd get going and see if I could pull it off. Taking a hint from the Bad Obsession Project Binky guys I started folding up cardboard (although I do know some CAD, this was my first time with Cardboard Aided Design) trying to replicate the crazy bracketry from Toyota.


Eventually (taking another hint from Bad Obsession) I set out to create a "negative jig" that I could build on so I wouldn't constantly be trying to fit things in the hole in the truck. I started with this plate:


And then lots of little bits shimmed up here and there. Bolted some angle on to the original stereo mounts and built structure back to the plate.


Lots more head scratching (I have a little $90 Grizzly brake which I love, but it does not do deep work) and I started welding up the box that would be the frame to hold my stereo panel. At this point, I'm sure hoping this is all going somewhere.


After a first test fitting with the hole cut in the middle of the frame, i see that i don't need to try to replicate those silly push-in clips:


I can just bolt the frame through the same holes with a wide-flange nut, like the weld-on nuts i bought to hold the ram mount on the top... (The amount of time i spent thinking how to replicate these... good lord). Some little bits get cut out, drilled, and bent up...


And voila, the finished frame:


Next on to the actual panel. I thought of having this waterjet or lasered in aluminum, but after a couple quotes I decided i would do it myself, and maybe use this as an excuse to finally get a DRO for my mill. 30 years of using this thing, and I finally have a DRO. Feels like a new machine! It still didn't prevent me from making the part twice, but oh well. (And it still has one goober!) Cutting the panel holes:


Making the brackets to hold the stereo:


All ready to paint:


And suddenly, it's time to be done making crap and start putting it in the truck! The 11-year-old comes in handy:


All mounted up...



What we've got here is:

• iPad mini held in a Ram mount, bolted to the top of the frame. Pass through USB Power. Off-road Nav is awesome on the ipad, plus it's a nice place for reference PDFs on radio stuff... plus music, etc etc. I need a shorter ram arm, I think.
• Since the iPad does NAV, i've got a nice but simple Pioneer stereo for radio, BT audio and, ready to accept ham radio audio... that's next.
• Contura switches to control winch, power radio, stereo, and USB from either battery (either ignition controlled/main battery, or any time on aux battery)
• Original hazards switch, clock, and airbag/alarm indicators.

Now, nothing but the stereo is wired up, so there's a lot more to do, but i'm glad to have it all assembled!

 

Woah. You need to sell those!

 

Crazy awesome work! You have great fabrication skills/ I love it when people say "I'll just make that myself". Keep up the great work, can't wait to see what's next.

 

Wow!!!!

 

Hah! I'm way to slow... but i'd *happily* share info with anyone who wants to make a go of it. There are a couple industrious fabricators out there...

Thanks guys! I appreciate it!

 

Sub'd. Amazing work sir

 

Dang, this is some awesome work. Props!

 

Thanks! As with all first tries there are some issues. I need to work on a better fit with the factory hazard/clock pod and a wicked buzz has shown up. Got some gasket material to try but I think I might be welding in a gusset to keep the radio even more locked in... dying to get it all wired up...

 

33" (255-85-16's) Spare Stuffing

After driving around with my spare in the back of the bed for many months, I finally tackled the spare lift/33" mod. I don't know why I've been putting it off. It was pretty easy. First step, bend the OE spare brackets up out of the way. I thought i'd try the jack...

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First side worked out great. Second side buckled an I ended up pulling out the hammer. Wear earplugs if you do this! Loud!

Some folks spoke of needing to drill holes to move the elevator back, but there were two big lightening holes conveniently located right were the screws needed to go... I made a little pinch plate:

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So convenient! Didn't need to drill under the truck with crap falling on me...

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The spare fits... barely. I'm going to drive around a little and see if i get any contact from the rear axle. If i do, I'll be moving up my planned rear bumper buy....

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I'd be interested to hear if there's any rubbing.

 

Tool Mounts

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Nothing is ever as easy as think it's going to be... bought some mounts a while back and finally got them mounted. Thougth it would be a straight drill holes, screw screws kind of thing but I hadn't considered the need to stagger them to get everything to fit.



Had to make a little set of spacers.



But another item checked off the list!

With Axe:



And, pulaski:

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Radios...

As part of a larger project I finished the install and set up of a pair of Radios for the truck. First, an Icom IC-2730A VHF/UHF for general communication, and a Yaesu FT-857D for HF grins. I'm not even sure how often I'll have the 857 in there, but it's all wired up and pretty easy to get in/out.

Both radios are powered from my distribution gizmo, so they can be powered by house or main battery, individually. The VHF/UHF radio is under the driver seat, and has an NMO antenna on the back corner of the roof. The HF radio has an NMO mount located in the center of the roof, and is reinforced with a chunk of 16ga steel. I've got a Comet SSB-460SB for every day use, and a

$72 Comet CA-2X4SR CA2X4SR CA-2x4 Original Comet Dual Band VHF/UHF Mobile Antenna W/Fold-Over Hinge 140-160/435-465 MHz - UHF Male (PL-259)

Comet CA-2X4SR for use on the non-ham portions of the bands too... (works on SAR/MURS bands should i put the non-ham VHF radio in the truck)



Originally, i wanted to mount both radios under the driver seat and made this cool bracket:



But I didn't consider the significant length of the cable/strain relief, so during install the fine folks at Santa Rosa Cartronics discovered the the top radio's cables bonked the bottom of the seat. So, while they were doing the wiring for me, they also fabbed up little brackets to hold the radios.



I made a little bracket to hold the head for the UHF/VHF radio. I figure for HF i'll be in the passenger seat and will set up something temporary with a ram mount... (can you say "grab handle ram mount mod?")



For the HF antenna, i'll either be stringing up a wire, or trying out these "ham sticks" another member was talking about. They're really long - definitely not for use while driving. You can barely see it in this photo:



There's a fiberglass mast with a "loading coil" that you top with a 4' steel whip. You have to trim the whip to work the portion of the band you want, so I did a little of that work as well. Transmit, check the SWR, adjust, transmit, check SWR, adjust, trim, etc... KK6GCV transmitting....



Everything is working great! I think the only radio piece i have to finish sorting is somewhere to hang the mic...

 

I really like that custom headunit dash set up! Pretty neat!

 

Thanks! It was a ridiculous amount of work, but i'm pretty happy with it.

 

LIGHTS...



And, the last thing this weekend was finishing up the light install. A while back I got 3 Baja Designs driving lights, 8 rock lights, and 2 backup lights. Thought was to get them all mounted up myself and then have Santa Rosa Cartronics to the wiring...

The BD light's mounts are so short the lights rest on their front bezels so i had to make a little stand first. Step one, figure out where I wanted them...


Step two*, measure, cut, mill, drill, and paint...


Someday i might paint the hardware black.


But, about here, I had everything else for SR Cartronics ready (radios, battery setup, dash panel) and decided to have them place the rock lights, as they've done a ton of them, and just wire for the reverse lights and I'll get those installed when i finally pull the trigger on a bumper.

They did a beautiful job with the wiring and rock light mounting...


Switches courtesy of Air On Board USA.


Tonight I finished the job by tuning the aim of the lights. Here are the headlights alone:


And here with fogs and driving lights:

Thank you and goodnight!

 

Lights look great and a great job fabbing the bracket! Nice write up. I'm still trying to figure out my fogs, mounting square pods in a round hole. They sit back too far and I loose 1/2 the light

 

I read through the build great job! Our trucks are similar inrespects to build and intended purpses. As a welder fabricator I certainly appreciate the effort put into the fab work so far. The radio/ switch panel is an outstanding idea and well executed. The slider fab work was also spot on. Now you have me wishing I had the tooling at home, great.

 

Thanks a ton! Why just bolt something on when you can spend more money and time being obsessive??? W/R/T the fogs... I have the same problem - the recess in the Demello bumper is pretty deep. Not an easy place to get a drill either. But, i've got plenty of light at the moment so that's way down on my priority list.

Thanks a ton. I still have the pattern for the switch panel. I love it. Someone (not me) should be making these things.

 

I'm held to only small things rt now as I'm recovering from second shoulder surgery in a year. Ha I'm at pt rt now. Makes it a challenge breaking and shaping with 1 hand. When I get home I'll post a pic of what work is w 1 hand