Weekend Escape Build

I've been browsing this forum for almost a year now and figured it was time to post my build using a ton of info I've gathered from this site. I bought a 1998 evergreen pearl MT 4wd extended cab about 2 months ago after 6 months of looking. The truck had 244k miles on it and was in decent shape but had been in a side swipe wreck. The truck had everything I was looking for except an e-locker but I felt I got a good enough deal to account for buying a rear locker.

Build Direction
This is not my daily driver so I have a bit more freedom with the build
- Must be reliable for long trips
- Capable on and off road
Otherwise, it's pretty open ended but I intend to use it mostly for camping

Suspension
Front
- Total Chaos upper control arms
- King extended travel front coilovers with 650lb coils
Rear
- Allpro Expo rear leaf springs
- Bilstein 5100 shocks
- Allpro 4" rear shackles

Exterior
ARB front bumper
PIAA LED offroad lights
Smittybilt 8,000 lb winch with synthetic rope
Glasstite camper shell with Yakima roof rack
Spray-in bedliner
All-Pro extended SS brake lines
Front diff drop
Trail Gear BPV relocation bracket
ARB Awning
Ebay Snorkel
ARB OBA

Wheels & Tires
16" Method 701s
285/75-16 Falken Wildpeak AT3s

Interior
Paranoid Fabrications switch panel
Interior winch control
Sony head unit and Infinity speakers
Weathertech floor mats
Kenwood tm-v71a ham radio

Performance
JBA headers
Deck plate mod
K&N drop-in filter

Maintenance
OEM lower ball joints
Whiteline lower control arm bushings
Flush coolant
Flush brake and clutch fluid
Steering rack bushings
Flush power steering fluid
Sea foam

Current Plans
Install a second battery and upgrade wiring
Build a go fast camper clone
Upgrade speakers/amp/sub
3 linked D44 will inevitably happen in the next 1-2 years


When I bought it:


As it sits now:

 

Front suspension right after I installed it. I went with 700lb springs because of the ARB bumper, winch and I plan on installing sliders very soon but do they seem quite stiff. I may try out some 650lb springs in the future or try removing the swaybar.

 

Looks like a solid start! 660 lb coils with sway bar removed on my 2nd gen with bumper and winch feels soft. I'd probably try removing it first to see how you feel about it before swapping coil springs.

 

I have done a ton of work since the last post so I’ll start to slowly update.

I got the camper shell installed along with Yakima round bars and built a sleeping platform for the back with storage in the cubbies along the side.

The center panel can either lay on the floor for more headroom or sit level with the boxes on the side to allow storage underneath.

I’m planning to install an inverter in one of the cubbies along with switches for interior and camp lighting.

 

I did end up removing the sway bar but I’m still feeling the 700lb coils are a bit too stiff. The only additional weight I need to add will come from skid plates so I’ll make the decision after that.

 

Boxed my frame using Trail Gear plates in preparation for my swing out bumper. Don’t mind my mediocre welds.

I ended leaving the stock shock mounts.
I cut a hole in the driver side plate to slide over the mount and notched the mount on the passenger side and slid the plate behind it. I also drilled clearance holes to mount the proportional valve in the original position.

I will probably go back in later down the road and put in new shock mounts so I can gain some extra travel, just didn’t feel like the hassle for now since my shocks are still fine.

 

I bought a CBI trail rider 1.0 weld together bumper kit and after missing a few pieces in the kit and changing my mind I ended up ordering a CBI outback 1.0 and making dual swing outs for it.

I started with two A to Z mega spindles, a plate with holes for wheels studs from Barnes 4wd and 2000lb de sta co latches.

I used 2x3x.125 tube for the bottom horizontal supports and 2x2x.125 tube for the rest. I started with a solidworks model I created and began cutting metal to match.

My plan was originally to use pop pin locks to hold the arms open but there wasn’t enough room to easily mount them on the bumper so I changed gears and utilized gas shocks.

I ordered a victory 4x4 Jerry can holder and mounted it on the passenger side swing out. I also cut out holes for two rigid flush mount lights.

I will eventually weld up the trail rider bumper and try to sell it to recoup some of my money.

 

Bought some All pro sliders with kick outs and fill plates from a member locally and installed them. It seemed like a no brainer to weld them over bolt them as I would’ve had to drill 32 holes in the frame. Install was pretty straight forward.

 

I ended up pulling the trigger on an ebay snorkel. The fit and quality are great and I think it looks decent but I’m still regretting it a bit as it’s definitely unnecessary. My passenger side fender is a crappy replacement so it’s not a huge loss that I cut a giant hole in it.

 

Installed an ultragauge using a spiker mount. Was a little concerned the mount wasn’t super sturdy on the grab handle but it has worked just fine and is in a perfect location. Just need to figure out where to put a phone holder for gps.

 

Did you have any issues with your mounting bolt not tightening all the way?

 

No, it tightened up just fine. The only reason it’s not super sturdy is that the mount goes around the rubber portion of the handle, which allows it to move but it’s really not an issue.

 

Finally got the bumper powder coated and also installed an ARB awning. Next up is finding a place to mount a second battery, I’m probably going to make a mount under the bed where the spare tire used to be.

 

Got it out for a trip this past weekend. Thinking I’m going to need to upgrade from the Dakar rear leafs due to the extra weight from the swing out. Also going to be on the lookout for a supercharger to compensate for the weight gain.

 

That's a very nice setup, I just got a camper cap and plan on adding an awning as well

 

Been a while since I updated this and I need to get some more pics. I designed an overhead console and antenna mount for the tailgate and got them laser cut and bent them up in my garage with a press brake that I made.


This the model I created and used to create flat patterns that I then laser cut out for the overhead molle panel/console.


Not the best quality photos but this is the finished product. My intent was to mount my ham radio but instead just mounted the mic up there.


I ended up creating these 3 mounts that snap into the molle panel that I used to mount the mic cables and mic itself and 3d printed them. Again kinda hard to see in the crappy pics but I can get better ones if anyone's interested.


This is the flat pattern of the antenna mount I created that mounts to the tailgate latch.



Here is the finished product installed, I used a 3/4" hole for a NMO mount antenna.

Here is where I ended up mounting my ham radio. I bent the remote mounting plate and used double sided tape and a couple screws to hold it to the useless cubby right below the ashtray. The main transceiver is underneath the passenger seat, I still need to create a mount for it to keep it from sliding around. Also added a cheap phone mount that suction cups to the dash, it has been a lifesaver on long trips.

 

This was from a 10 day, 2500 mile trip I took with a couple buddies back in June along parts of the NMBDR and a few other random trails in NM. Only casualties were a broken marker light, a cut sidewall and the magnets came unglued on the motor for my locker which left me stuck with the rear axle locked. Luckily we had the tools to take it apart and re-epoxy the magnets back on.

 

This was a week long trip in August around Buena Vista CO.

 

Back to truck updates. I've since swapped around suspension a bit by swapping to 650lb springs for the front coil overs and Allpro Expo rear springs, not much to see there so I dont have any pics. Also added RCI IFS and transmission skids. Upgraded to Osram 100/90 headlight bulbs as I couldn't see a thing on the highway at night without turning on the PIAAs. I didnt do the wiring harness upgrade like everyone else does as it didn't seem entirely necessary to me as the bulbs draw around 8 amps and are on a 10 amp fused circuit and I've had no issues so far. I'm sure the higher gauge harnesses have less voltage drop and therefore brighter lights but just the bulbs themselves seem like a good enough upgrade to me.

I've also ordered a supercharger... about 2 months ago and am still waiting for it to come in with no ETA. In preparation for the supercharger, I checked the valve clearances (all were in spec), changed the fuel filter, upgrade the fuel pump to a Deatschwerks DW100, replaced the timing belt, water pump, thermostat, etc. I took the injectors to Injector RX in Houston and had them serviced (cleaned).

 

Now that's my kind of truck. Nice work.