Tacoma_2002's Build Thread

Sub'd AF

 

I had quicker than expected turn around time with the powder coating and machine shop. I was able to get all my parts back on Wednesday afternoon.

As mentioned before I had the machine shop turn down the OD of the IFS hubs to work in conjunction with the Tacoma brake kit from FROR. They were able to add 4 hub studs to the IFS hub and drill the lockout to match. This should bring some new found strength to the stock Toyota setup.



I took time to sand/prime and repaint the wheels on Wednesday night. They turned out awesome. This is a picture after one coat of semi-gloss black. After a few more coats they should be 10-8.



The housing looked killer after powder coat...way better than I anticipated for sure.





Right now I'm battling some issues with the steering shaft/shock tower. I cut the shock tower and put in a 2.5x2.5x.250 wall square tube to help clear, but due to the angle the shaft will run toward the firewall I'm still having issues. The shaft needs about 1/8-1/4" clearance on the front side to clear comfortably. I'll be taking care of that this evening hopefully.

 

For the first time in this project I've had to take a couple steps backwards. A little disheartening at first but in the grand scheme of things...not so bad.

The plate coilover mounts that I bought from CU ended up falling 5.75" short of where they needed to be. I cut them and extended them so they would be the correct height. Then comes steering shaft clearance issues. I notched the tower for the shaft to pass through but due to the angle that the steering shaft runs it was hitting the back side of the notch. Unfortunately the notch was cut to the maximum. My options were to begin notching the towers (without replacing the removed material) and sacrifice structural integrity or get to bending tube...

I've been bending tube the past day or two. I finally have the towers dialed in to my linking. I just need to get to the shop and build some mounting tabs then get to welding.

Yesterday I had hoped to completely build the axle hub/hub. As I was laying all my parts out on the table I noticed a couple of critical pieces missing. The Birfields nor the inner shafts came with birf C clips or the clip that goes on the outside of the birf to hold it into the hub.

I called TG only for them to tell me neither product comes with clips...I guess they'd rather sell you the $4.50 c-clips separately....I would highly suggest they advertise this so someone else doesn't fall a week behind waiting on bullshit parts....oh well.. After a call to Luke at Frontier 4x4 I have the parts coming... I don't like the fact that this axle housing doesn't come with a full sized drain plug (you have to remove the two bottom studs to drain the housing) so I went ahead and ordered a 1.5" inspection plug while I was at it...at least this will give me an idea of how my internals look since I don't have a large enough hole for trashed gears to fall out of...

 

Awesome work man!

 

Thanks! Should have the 30 spline C-clips in toward the end of the week. Then the saga continues...

 

I was able to get the inspection plug hole cut and the plug welded in. After that I took time to build the axle completely....I love the way everything worked out...especially the FROR Tacoma Brake kit I got from Brian! I buggered up the powdercoating when doing this but I have some touch up spray on the way.




A lot has changed...I'm not one to audible and deviate from the original plan, but in this case I had to. I bent some shock hoops using 1.5"x.120 tube...after they were in place I made a template and built some shock tabs. This left me with nothing to do but add a tower brace across the engine compartment to tie the towers together. I did not have enough room for the tube to go across the top of the engine due to hood clearance. I had previously thought about just adding a tube across the back of the engine to the other side.


After some contemplating I decided that with the bends of the tube this would be a weak point...I went ahead and added a piece of tube across the front of the engine as well to eliminate this possibility of bending.


Once this was done I was able to put the wheels and tires on then sit the truck on its own weight...this is 'almost' at full compression...I'll have to tighten the coilovers up a tad to raise the ride height...Frame is currently at 24.5"!




Now I'm having an issue with the panhard bar mount contacting the coil spring on the passenger side...I'll need to cut it loose and move it Driver about 2" to correct. Other than that and adjusting the coilover preload....we're closer to home!

 

I moved the panhard bar mount and adjusted the preload relatively close to where it needs to be. I was curious about how much fender I was going to have to trim, so out comes the fork lift!



I had to stop lifting due to the tire being in contact with the fender inner supports. Not a huge deal as they're removeable. Next will be trimming fenders and some of the inner structure away to eliminate the possibility of the tire being cut while flexed and turning.

The goal for this week is to finalize the steering (tie rod and drag link), shorten the panhard bar and get the radiator back in so I can have a high pressure PS hose made *hopefully* before Christmas.

 

Sub'd. I like it!

 

So the last month has been spent on relatively boring items that I didn't bother to document. A lot of disassembly and reassembly to get everything just right.

I had started tube work and on the second bend the compressor took a dump....luckily a $50 capacitor, and a 2 week wait, put it back in business!

Before the tube work began I took it down the road for the "maiden voyage"...



With the exception of the steering wheel needing clocked, I was pleased.

Then it was time to give the bender a work out...





Most all of the long runs are now bent and tacked into place. I still have to align the short pieces along the extended cab before tacking them...oh yeah...and about another 100ft of tube...

 

After some time, frustration and serious help from friends I was able to get this exo and tube bed semi complete.

Tube bed shaping up.


Its the details that makes something 'yours'...unfortunately these details take some time to get like you want it...



I painted the bed sides white on the outside to see how I'd like it...



Front bumper section is not complete until I get the winch mounted (this unit was used for mock only). I plan to add some plate around the fairlead area and below the winch plate...

 

At this point it was time for Mardi Krawl 2018....so I shot some black paint on the tubes and bed and took off for Tuscumbia, AL.





I have a few small kinks to work out and I still have to add tail lights, winch and several misc. tubes for cosmetic purposes...but overall I was happy how it worked.