Box Rocket 1990 SAS Hilux

Recently picked up a 1990 Regular Cab pickup to build with my son. This is so similar to my old 1993 pickup and it's bringing back lots of memories. Bought this one from a friend that had started cleaning up some shoddy work from a previous owner. It's now it decent shape with only 143K miles on the truck. There's obviously still a lot of work to do but it runs great.

Here's the highlights:
Solid axle swap
5.5" lift
brand new 22RE
5-speed
dual transfer cases
5.29 gears
rear locker
new 35" swamper SSR's on MT wheels
custom front bumper with winch

It came with 3 sets of doors (tube doors, factory doors in awesome shape, 2nd set of factory doors that are kinda rough and will be made into half doors.) The body is almost completely rust free and the panels are all in good shape. The bed obviously needs a bit of body work but it's clean and straight. Plans are to bob the bed and get body work done soon so we can get some paint on it and get it put back together. It also came with a second bed and a free wheeling trailer axle to build a matching trailer. We're looking forward to finishing this truck and doing more wheeling.

1990 Hilux by Adam Tolman, on Flickr

1990 Hilux by Adam Tolman, on Flickr

1990 Hilux by Adam Tolman, on Flickr

1990 Hilux by Adam Tolman, on Flickr

1990 Hilux by Adam Tolman, on Flickr

1990 Hilux by Adam Tolman, on Flickr

 

spent the day yesterday improving the departure angle on the truck.

Untitled by Adam Tolman, on Flickr


I spend about 2 hours measuring and making marks until I was happy then started cutting.

Untitled by Adam Tolman, on Flickr


In the end, I removed 12" from the bed. This way if we ever wanted to put a topper on the bed a 5' topper will still fit.

Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


you can see that the frame had already be cut and capped just behind the shackle. This saved us a step of having to cut the frame.

Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


Instead of just butt welding to back end back onto the bed I removed a strip about 1.5" wide to use as a backing plate. Drilled lots of holes and plug welded the strip into place, I'm sure many of you have seen this method before.

Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


the test fit.

Untitled by Adam Tolman, on Flickr


Then got it all welded up. Next up is to sand the bed and do a bit of body work to prep for paint.

Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr

 

Cleaned up and de-chromed the grill and installed some new LED headlights.

Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr

 

I'm working on several things with the truck right now. One minor thing was I bent and welded up a bolt on light bar for the front bumper. Still working out what lights we're gonna use but the tube to mount them is there now.

Untitled by Adam Tolman, on Flickr


Also, I've been teaching myself how to do vinyl wrapping and I've got the front fenders and hood wrapped now. I'm really happy with how it's turning out. We'll see how it holds up but if it is good for a couple years while I build up my space and equipment to do a full repaint that will be enough. The vinyl is from Avery Denison and the color is Carmine Red. I also did a satin black overlay for the center of the hood.

Untitled by Adam Tolman, on Flickr


Untitled by Adam Tolman, on Flickr


We're getting the bed sanded down to bare metal and ready to do a skim layer of filler to finish it off before wrapping it.

Untitled by Adam Tolman, on Flickr

 

few more updates. First off, I've been fabbing up a rollbar. I wanted to do something kinda unique and I like the lines of a lot of prerunner cages. So this is "inspired" by the lines of a prerunner cage. The plates connecting the main hoop to the angled legs obviously are not upper shock mounts like they would be for a true long travel prerunner. But it will provide some extra bracing. I decided to make it somewhat modular and have it mostly removeable. The main hoop is the only permanent part and the rest can be removed pretty easily. Sleeved bushings at the top of the main hoop, Plate braces are bolted to main hoop. It's also tied into the frame with matching foot plates under the bed. I could have done more traingulation but I wanted to keep the bed as open as I could. There will also be an in-cab cage at some point so I feel pretty comfortable with it.

Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr


Roll bar by Adam Tolman, on Flickr

 

The other update is the rear bumper. This was a "make-it-up-as-you-go" design. I just built it from whatever steel I had on hand. Main bumper is 3x4" rec tube. Wings and center section are 3/16". DOM corner guards. Full 1" thick recovery points. I still need to finish up the frame mounts. I wanted to reinforce the bumper where the recovery points are, but I might have got a little carried away. 3/16" plate and split piece of DOM to spread the load of the recovery points.

Rear bumper by Adam Tolman, on Flickr


Rear bumper by Adam Tolman, on Flickr


Rear bumper by Adam Tolman, on Flickr


Rear bumper by Adam Tolman, on Flickr


Rear bumper by Adam Tolman, on Flickr


Rear bumper by Adam Tolman, on Flickr


Rear bumper by Adam Tolman, on Flickr

 

I got a huge adrenaline rush looking at this thread. Sweet project!