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Tacoma_2002's Build Thread

Discussion in '1st Gen. Tacomas (1995-2004)' started by tacoma_2002, Nov 21, 2017.

  1. Nov 21, 2017 at 6:24 AM
    #1
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    After much anticipation (and parts collection) I'm now ready to begin a build thread here for my ride. I've had the truck since 2004 and it has undergone many phases in its time. It started with a Corn Fed spacer lift (some of you will get a chuckle if you remember that guy) and AAL with 285's....history shows this was just enough to really get me into the offroad scene.
    cornfed-png_a09504728310705cb02a3ba809ea010b202bf5e9.jpg



    TTORA TakeOver 2009
    takeover-png_a77cc88ea2614d1e3a12105bab4efe696c013842.jpg
    takeover-2-png_de47eb29b44497426f8146e8d3f6cd34ef16b7ab.jpg





    After that I started buying armor, building bumpers, buying coilovers etc etc. You could say I was hooked ;).


    bumper-png_b3f22066a864164ada3c5bf1ebd3a3b7a4f13abe.jpg
    comparison-png_fa7ff31254011a3c4da2705eca4b6931900c0523.jpg
     
  2. Nov 21, 2017 at 6:25 AM
    #2
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Male
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    This vehicle was my DD for years (135k miles) so I had to keep it as street friendly as possible. I went back to stock wheels with 285 KM2's, Fabtech 2.0 coilovers, Custom front bumper, Sliders, Rear bumper and Ubolt flip. The truck daily drove and wheeled configured like this for several years.


    delta-dd-png_740f4b887304b8a3d25879b84a4d3f0c5ade014d.jpg

    fabtech-png_810bdb68c5ed2def3b64f87024f475df6190ff51.jpg

    tube-doors-png_fdf45cae950ef04cace2d90e5df596afe8cad4b7.jpg
     
  3. Nov 21, 2017 at 6:26 AM
    #3
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    FINALLY there came a time when this was no longer my primary means of transportation....that's when things got fun. First off was to make room for 35's by tubbing the firewall.
    firewall-tub-png_aadfa5cf8b601e3b27311209afb3eafb21b3801a.jpg
    35s-png_f8fc356640001ff138d76e61af00090277d31e79.jpg

    Then we got some Steel wheels and suspension seats...

    wheels-png_85bd9f9e363588788ce63dfc854a7b1c9e3582c2.jpg

    seats-png_db02057f2c1677892274fdca4d6ded5e08ef0533.jpg
     
  4. Nov 21, 2017 at 6:26 AM
    #4
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    Shortly there after some really COOL boxes started showing up at the shop!
    dual-boxes-png_1691b30efe8ac5f7afb4e1b5bb0d8226e7ead91f.jpg
    goodies-png_a56690a2eddde6f630c1bfa5c16b431711e8d9a8.jpg


    DUAL CASES! Shout out to Brian at FROR/Diamond for his superior customer service and great crossmember!
    cases-assembled-png_5b9e4ecc0c9e7129772606cfc3ab4079b4020eb1.jpg
    fror-png_610d16beb8abfd8c51f8bd699cc5c740ef123368.jpg
    interior-cut-png_a796f7184fc212e449cdcda83afb02699cf37c91.jpg
     
  5. Nov 21, 2017 at 6:26 AM
    #5
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Messages:
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    Male
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    interior-done-png_a3de793425f19d3a73ae10df39bf224daf373423.jpg

    Dual cases....DONE!
     
  6. Nov 21, 2017 at 6:27 AM
    #6
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    This is the "Last Known" picture of my truck on wheeling in its last configuration....bittersweet...

    last-wheeling-png_142f94ff2cc505096d7619c4ca2716ecdfcf906e.jpg


    Now that's out of the way...on to the good stuff...anyone notice the 39.5" Irok in the background yet?

    40s-png_0ff43a81fbc2ce245966b34d88bf68b5dd83ddfa.jpg
     
  7. Nov 21, 2017 at 6:27 AM
    #7
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    Then....MORE REALLY COOL BOXES!

    rockassault-png_b5d0051b0879b2fec8e5d3e9345acee238265184.jpg
    ra1-png_bb578ca7efe7d0dfbcaef05b5d2bc65d0a6f7325.jpg

    Longfields....30 SPLINE!!!
    30sp-chromo-png_2e90d74758ee9ae211c267b29b3e12703f2f7aab.jpg

    Thanks to Global Offroad and Pepe Palomo for hooking me up with the TG stuff! It's always a pleasant experience dealing with Pep's!
     
  8. Nov 21, 2017 at 6:28 AM
    #8
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Member:
    #8394
    Messages:
    171
    Gender:
    Male
    First Name:
    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    img_1995-jpg_0748dd65b86a47549d27a54d0effa508a3f071b2.jpg img_1996-jpg_18184c3087f5532ce0de412e9af7a397c80c11e0.jpg THIS is why we're upgrading. Last wheeling trip out got the best of my front diff (again).
     
  9. Nov 21, 2017 at 6:29 AM
    #9
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    With that being said. Let the cutting begin!!!! img_1994-jpg_d75a27c7839a2ffa80619ef54ad7ba7f3bc9a8e0.jpg img_1998-jpg_a61c49c3af5c7a26e616a08951260182097088a8.jpg img_1999-jpg_9a26276b3f62648a5dffc034caedc4f29949a51e.jpg img_2001-jpg_639c3baf42c1e89b896c178dcfa4f56d6030f6fc.jpg
     
  10. Nov 21, 2017 at 6:29 AM
    #10
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Messages:
    171
    Gender:
    Male
    First Name:
    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    img_2006-png_3df70d4a023f5488e02739f3c07becf052efa168.jpg

    Kinda how my wife felt to see all this stuff removed....I feel your pain little shock tower...
     
    Jstand likes this.
  11. Nov 21, 2017 at 7:46 AM
    #11
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    I got the frame all cleaned up and ready to box and weld off the engine mounts. I will be mounting the steering box and plating the frame next. img_2009-jpg_2ee3da3ce3ee1a9ff58c0918af62b4bc1db3d789.jpg

    I set my pinion angle and tacked the lower link mounts onto the axle housing as well.
    img_2010-jpg_d6acdb19da19ab44cd5e97ba9c4e3447c9c54561.jpg

    After some looking it appears that my front bumper will have to be totally rebuilt. When I originally built the bumper the plan was to use leaf springs and key off the front bumper crossmember with the leaf spring hanger.

    My mood has shifted and I would now like to incorporate a winch into the front bumper. The bumper is 1/4" plate and its just going to be too heavy by the time I add a 9.5k winch. I'm trying to keep the coilover spring rates as light as possible for maximum ride quality and flex.

    My goal is to have the steering box mounted and frame plates built and on this weekend. I plan to get a materials list together and pick up everything I need to build the steering shaft next week. Word on the street is there might be some hydro assist on this thing...
     
  12. Nov 21, 2017 at 7:47 AM
    #12
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    '02 Tacoma 4x4 TRD
    I burned the midnight oil last night and got a few more things done.
    img_2022-jpg_9312d3269c200aa942ccae3d128fc6335645880e.jpg

    I was able to get the steering box located as far forward as possible. This required some modification to the TG steering box plates since the Tacoma frame narrows toward the very front. No big deal but time consuming.
    img_2024-jpg_65dbfdfc020545c82464e01d9a51e607d03f5473.jpg

    Plenty of room for Hydo lines
    img_2027-jpg_c872dba29a84389406f5aebb9adc342f9cfd1c81.jpg

    Passenger frame plate done with the exception of a little more welding and grinding. I already had the frame pretty warm so to keep from having too much heat soak I stopped.
    img_2028-jpg_609da40a994db48ea6d07d30078f98f2a5d7044c.jpg

    Nothing motivates you quite like rolling a tire under your far-from-finished project hehe
    img_2030-jpg_e1cd42f3508457d8727ff34cc6580f17001f935f.jpg

    I believe my frame height will rise +/- 2" from this. I had planned on that early on but for COG sake I'm still shooting for 26" (currently where the truck is sitting).

    Sheet metal trimming along with time, will tell.
     
  13. Nov 21, 2017 at 7:48 AM
    #13
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    For the steering I frankenstined my own piece. I disassembled the u-joints on the factory Tacoma shaft and reassembled them creating a single U-joint setup. I cut the shaft after the firewall (where the shaft tapers down) and attached a 1st Gen mini-truck "slip" shaft to the other end. Finally got it cut to length and mocked into place.

    steer-png_f5132a6453cd3486d9d9612ddecb21777e84d34c.jpg

    As you can see I need to do a little brake line re-routing as well as secure the wiring harness out of harms way.

    steering-png_1a90425780047bca08b0a4ef6a92509d2e9ffe40.jpg

    Overall I'm happy with how it turned out.


    So far on this project I've used all Chassis Unlimited brackets and tabs...I'm very impressed with their Laser Cut CNC pieces (to say the least). If possible I will use every tab and bracket from Chassis Unlimited from here on out..

    bracket-png_1f93f45b81cf19695cd28b566127209b23f8e5eb.jpg

    So far its looking like my lower links will be in the 40" range and the upper link will be in the 41" range. I have a 20* offset on the upper link at the frame with 3" of separation. If all goes as planned I will have 10" of separation at the axle with the upper link sitting at 15.4*. Since I expect my ride height to grow an inch or two I'm not 100% certain on what my lower link angle will be but I'm trying to keep them as parallel to the ground as possible.

    I'm not 100% certain what these numbers will put my Anti-Dive value at...and with this being a truck build I don't have a lot of options as far as link separation goes. With all of this in mind (and if my math is correct) I should have a very manageable anti-dive % when its said and done.
     
  14. Nov 21, 2017 at 7:48 AM
    #14
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
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    Vehicle:
    '02 Tacoma 4x4 TRD
    I've been working on the final geometry of the suspension over the last week or so...double checking numbers and formulas etc. I finally nailed down some final numbers that I'm happy with so I went ahead and cut some lower links. After getting everything squared up I tacked it into place.... This thing is finally beginning to look like something! I've also been working on small details such as motor mount gusseting and plating off that I have not documented. I was able to complete the driver frame plate and get it into place as well.

    I will not be able to use the upper link mount that I purchased from Chassis Unlimited due to clearance restrictions. I'm planning to build one this weekend so I can cut and install the upper link.


    Pinion angle set at 3*

    1-png_6304dbdbb31c099b1fa4224e5085a6edf9e67cde.jpg

    Passenger side link mount in place.

    2-png_24dfab7499e10f1ca6eb2716306578524a8a4260.jpg



    3-png_69041ca758c5cbda29152f2027a9d24f25f7d239.jpg


    Driver side lower link mount tacked into place. Link angle at current ride height is 9*. As stated before I'm hoping to lower the ride height so this number will go down some with that.

    4-png_be3de71fcdb541bac9310c8a4df456170db02a6e.jpg


    Driver frame plate tacked into place.

    5-png_cbe1e9eec679c7f4c88331549d50e370f94183ed.jpg

    I moved the front axle 3" forward from the stock location. This made my final wheel base 125"...not happy about that but I'm planning to back half and shorten it to 112-114" next winter. With that being said I will likely move down in tire size and lower the truck some more when that happens For now 125" and 40" tires will have to work.

    Current frame height is 28".
     
  15. Nov 21, 2017 at 7:49 AM
    #15
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

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    Vehicle:
    '02 Tacoma 4x4 TRD
    As discussed before I was not able to find an upper link mount that would suit my needs. I opted to build my own to dial in my link separation as well as direct the link away from the oil pan. I still plan to box the upper link mount across the front and back side to prevent the mount from shifting horizontally under load. So far this is what I have.

    1-png_c481b193248ca66dc5dc2ed6c5b893a7dcc57bb6.jpg

    I cycled the axle some to make sure I didn't have any binding issues...seems like this thing could have twisted for days...too bad I'll have to limit the travel with straps and bump stops :D

    2-png_ce1184b00ae5927f05eb70f42df97ec78e7a1928.jpg

    3-png_95ad81d26b5983cb4713b54703ec7e42e4466b2c.jpg



    My next task will be plating the upper link mount and working on getting all the steering linkages cut to length and put into place. I still have to disassemble the steering box and drill/tap for hydro assist as well.
     
    LukeCC likes this.
  16. Nov 21, 2017 at 8:27 AM
    #16
    boostedka

    boostedka Well-Known Member

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    NM
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    DAMN! :eek: That's some sic work so far! I'm definitely going to be following this build! :thumbsup:
     
    tacoma_2002[OP] likes this.
  17. Nov 21, 2017 at 8:33 AM
    #17
    PROseur

    PROseur Well-Known Member

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    Beautiful

    A real build ! Not just some plasti dip emblems and tires that kids call a build these days

    Wife must be understanding with you being away in garage always :D

    Nice Suzuki
     
    tacoma_2002[OP] likes this.
  18. Nov 21, 2017 at 8:43 AM
    #18
    quetzal

    quetzal Well-Known Member

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    Mario
    Long Beach, CA
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    All-Pro UCAs, King 2.5 C/Os, All-Pro Expo Leafs, Bilstein 10" Shocks
    Cool! I'll be watching this thread.
     
  19. Nov 23, 2017 at 1:34 PM
    #19
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    Andrew
    Cotton Plant, Mississippi
    Vehicle:
    '02 Tacoma 4x4 TRD
    I've been farther behind than I planned due to some unforeseen circumstances.

    I ordered an oil pan and pickup tube from a member of this forum and after receiving it, I realized the oil pan was not for a 6 cylinder engine. I contacted the member and we were able to work out a resolution on the unusable unit.

    This left me needing an oil pan and pickup tube...

    I ended up traveling to Chariton, IA to Frontier 4x4 and buying an entire engine that came complete with the oil pan and pickup tube I needed. Not only was I able to get an oil pan and pickup tube but now I have a spare 3.4L engine. I spent some time with Luke in his shop looking over his 4runner and discussing my build. Luke was a super nice dude to deal with. I would highly suggest doing business with him if you have the opportunity.

    and thennnnnnn....

    My wife hit a deer with her Highlander and 'temporarily' put it out of commission. I had to devote most of my time to my '97 FZJ80 thereafter to make it 100% roadworthy for her to drive. After a knuckle rebuilt, new radiator, oil pump o-ring, distributor o-ring and full service she's on the road while I fix the Highlander and carry it in for paint.

    Constant resistance.

    I did recieve my coilovers last week (6 weeks exactly from order date). These things look freakin' sweet!


    2-png_62eb3fe9ae14792392ce3dea5cb831ac1f99204d.jpg


    I spent the last few days working on the Tacoma's steering and panhard bar placement. I was able to get the shock towers and lower coilover mounts tacked into place and the coilovers on. I'm sitting about 5" above my planned ride height at the moment (frame at 29.5" with the axle centerline at 17") BUT I don't have the steering box, battery, radiatior, front bumper etc in place. I'm guessing it will settle about 2-3" with all of the weight added but that still leaves me needing to lengthen the upper shock towers by 2-3". Not a huge deal but still kind of a PITA.

    As it sits now...

    1-png_b73489d58f336aaafc2afed4ca8a90f25fb83388.jpg

    For now I'm leaving the towers in place and starting to burn in all the link brackets and frame plates.

    The few things that I've done undocumented include rebuilding of the steering box and drill/tap for hydro assist.
     
  20. Nov 23, 2017 at 1:36 PM
    #20
    tacoma_2002

    tacoma_2002 [OP] Where We're Going We Don't Need Roads...

    Joined:
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    '02 Tacoma 4x4 TRD
    As of now all the finish welding is complete. I was able to get the axle housing off to the powder coater today and hopefully will get it back the middle of next week depending on work load/schedule with Thanksgiving being this Thursday.

    housing-png_9943b00a8dc00826d516a7156fa075a3dfa73933.jpg

    I sat down a week or so ago and drew up a sketch for some rim stiffeners/rock rings in a CADD program. Pretty basic design but I think they look pretty cool. I send the drawing to Southern Steel in Memphis and had them Laser CNC them out of some 3/16" plate.

    rims-png_ff4c1eb903d4255ae90b5d2c436bdd46bf952998.jpg

    One wheel finished...or so I thought. I ended up having some pretty heavy grinding marks show through the paint. I'm going to sand them down with some 120 and 220 before hitting them with a high build primer and paint. You can see in the picture the grinding scars that I speak of...

    rim-png_f2c4bb89057176bbdd9794f437af22ef737523d4.jpg

    I tried to blend most of the welds into the frame so it'll have a "factory" look when I'm done. Here you can see where I blended the frame plates in with the steering box plates/mount. Not too bad....lots of work.

    frame-png_78ece21fe3cfd969b6e471f2eb3f3a8106381d52.jpg

    I had a winch plate that I'd drilled out into some 1/4" several months back. I just now got it into place with a few good hot tacks. The goal is to leave the front bumper as least bulky as possible. I'll end up cutting the corners of the plate off at an angle and attaching some tube work to it when the exo cage starts. For now you get an idea of how the winch will sit.
    w-png_7fa961e67a514db0d75dbb8acc5477b11aafe71f.jpg

    Yesterday was spent mostly cutting and lengthening the shock towers. I ended up adding 5.75" to the Chassis Unlimited plate shock towers. Predicted frame height will be 25-26" with zero preload on the coilovers.

    I dropped the hubs off at the machine shop to be machined to accept the Tacoma rotors as I'm using the brake kit from FROR. I left the lockouts with the machinist also in hopes that he can add 4 more dowels to the hub/lockout mating surface for strength. Hopefully I'll have those parts back by mid week.

    Stay tuned. The next post will the the truck sitting at ride height with tires/wheels :)
     
    boostedka likes this.

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