[LONG] "Moon," the super-stock semi-stealth resto-mod camp build (09 Access Cab TRD)

I’ve been combing TacomaWorld for many years now, and completed a multi-stage refresh and modification of a 2009 Access Cab TRD, MT, 4.0L, last year that I picked up in early 2021. Thank you to all who have contributed knowledge in this forum – it has helped my process immensely.

I picked up this 09 used as a blank project canvas. The prior owner had all the maintenance done by ToyotaCare, so the core mechanics were in good shape, and the truck was bone stock. The prior owner had only added steps to the side of the truck, and had very clearly never taken it off of improved roads. Otherwise, the truck was pretty beat – it clearly sat outside for its entire existence, given the faded paint and headlights and chassis finishes teetering on the edge of being lost to road salt. And on the drive home from the dealer, the driver-side CV axle boot split, which couldn’t have been better timing given the project plan to gut it and start over as something of a resto-mod.


(Final draft shown.)

The following build thread is a summary of ~1.5 years of work, and many prior years of research, planning, and budgeting for this build.

Built for a Purpose
I intended this build to be road-to-trail and trail-centered for trails in the rocky mountain region, and not as a daily driver. I also intended the design to be more of a sleeper and appear closer to stock than heavily modified, hence keeping the original TRD wheels (and adding one to be the spare).

All storage of gear and such is kept low in the vehicle to keep the center of gravity low for trail-use, hence the lack of roof racks, and all items (tools, spare parts, camping gear, etc) being kept under the deck in the bed and behind the seats.

Overall, the build is intended for exploratory off-road use, can do a little of everything just shy of being so modified that it gets trailered to locations. It’s intended to be right in that sweet spot where it can be driven on highways pretty comfortably, but then can spend the rest of the time off-road, and also get home.

The Photo Montage
Early 2021, I found and bought the truck the day they released it on the lot and before pictures were taken, thanks to the conditions in early 2021... the blank canvas.



It had plenty of little problems.


I started replacing parts that were beat, including lights, grille, and I added a topper.


Trucks have changed since the '90s, given how low the Tacoma is next to my stock-height '95 Nissan D21 Hardbody with stock-sized tires ...


I designed and build a custom deck / false bottom / organization system for it (added weight first, then built suspension to size / weight).


Then, I made some home-made camp pads for the deck.


For less cowbell, I had the exhaust cross-over rerouted by a local exhaust shop.


Then, I put it up on jacks for two months and gutted the entire suspension and final drive.


I scuffed it all up to prep for the refinish...


And thanks to ECGS, I refreshed the diffs with seals, gaskets, 4.30 gears, the famous ECGS clamshell bushing, and I repainted it, too...


Fresh paint.


And the rebuild begins (SPC UCA, Bilstein 6112 + B12 springs shown).


I bolt-map everything, and torque everything to factory or part MFR spec (always).


I cut off the cursed leaf spring hangers with a cutoff wheel and an air-hammer.


Finished the front refresh/rebuild!


Repainted the tailgate with PPG paint and [partially] re-badged it for that stock-ish look.


Added BAMF rear-hangers after the refinished, and modified the shackle bushings to deliver grease to the new poly bushings via the grease-ported bolts (sprayed with moly paint for a lil extra):


New Alcan springs in, rear third member in, ready for next steps.


Fully rebuilt the rear axle assemblies, including new Koyo bearings. (Awful job even with a press and job-specific tools, btw.)


Full refresh of the rear drums, including turned and re-painted drums.


Put finishing touches on front, including new skirts and Spidertrax spacers (long story as to why...)


Rear done, too. Magnifico!


Back on wheels, ready for new tires and alignment.


First photos out of the garage, it's rolling!


New shoes added! They're not fancy, but they're available everywhere in this size in case a replacement is needed.


First shakedown run, circa May 2022... (success!)


Subwoofer delete and electrical box added.


Tent system prototype complete, concept proven, patent pending!

And now I'm working to get this tent into production for Tacomas, and eventually other trucks. Can follow on Instagram if you're interested: https://www.instagram.com/perch_equipment/​

Cut off the booty to clean up that exit angle and protect the body from inevitable trail damage...


Home painted the ATH Fab high clearance rear bumper and skateboard decked it.


Color-matched the ATH Fab rear swing to keep it looking stealthy. This thing ROCKS, thanks Morgan!


Shakedown run 2! Now with swing arm...


And now for the front with the ARB Deluxe bull bar, including a custom rewire job of the winch control box, plugs, and power leads to make it all stealthy and only receiving power when I want it to ...





Final exhaust reroute before and after. (Less cowbell.) Before...

After...


Happened way back in the earlier part of the project, but here are the CBI front and mid-body skids (sprayed at home):


And I'm spent. Now, it's just trips and fine-tuning. Looks a little stock-ish, a little stealthy, and everything on board fits under GVWR and the payload capacity limit when fully packed. Huzzah!


Core / Tech Details of the Build

1. 
   
   
   • ~1.5-2.0 inch lift with Bilstein 6112 + B12 spring struts up front
   • Bilstein 5160 shocks in rear with Alcan springs with +750 Lbs capacity, and replaced OEM leaf spring hangers with BAMF hangers
   • Replaced UCAs with SPCs, and replaced LBJs with Mevotech TTXs
   • Replaced swaybar endlinks with Mevotech TTXs, as well, and replaced swaybar bushings and brackets with Energy Suspension urethane + greasable brackets (yep, keeping sway bar)
   • Replaced OEM CV axles with CVJ remans with the works, including HD outer boot and Toyota inner
   • Tires changed to 265/75R16 (31.6”), Goodyear Wrangler Duratracs (123Q-E1 rated)
   • ARB Deluxe bumper in front with Warn VR8S Evo winch
   • High clearance rear bumper with swing arm by ATH Fabrication, home painted with black on bottom, Toyota color-matched Super White II on top
   • Rock sliders are RCI Off-Road, bolt-on
   • Front and mid-body skids by CBI Off-Road in steel, painted black
   • Refinished chassis with blood, sweat, tears, and POR-15 paint
   • Regeared diffs with ECGS cores to 4.30 with the works, kept the rear factory E-locker, and kept the front as an open-diff. Crawl ratio is now 46:1, rather than stock 39:1 -- the marginal edge makes a big difference for most of the roads I'm on. 4.30 chosen due to it being a happy medium of retaining gear strength, getting a better crawl ratio, and being able to stay just under 3k RPMs at 75 MPH on the highway (best for long trips).
   • Rerouted the [heinous] exhaust crossover and the rear tailpipe to fit the high-clearance rear
   • Added A.R.E. MX fiberglass topper with Windoor feature, ala Suburban Toppers in Denver
   • Custom-designed and made deck / false bottom with drawer and hatches
   • Custom-designed and made a tent system for the topper
   • Custom-designed and made camp pads
   • Added Bartact seat covers
   • Frankensteined together a combination of RAM Mounts with other mount products to hold phone and iPad
   • Husky liners for the floors
   • Removed stock subwoofer and custom-made an electrical box that allows for USB and car plug charging from the connection point in the rear – and connected a Dometic CFX3 25L refrigerator to that
   • Custom 5-point air system powered by a Viair 485c Gen2 compressor, patched into a switch on the dash
   • The next modification is the driveshaft – which will be done by Northern Colorado Driveline, to make a more robust driveshaft that retains the carrier to protect it from that slack break-over thanks to the long wheelbase
   • Speedometer corrected to perfection (+ 0.5 MPH) after re-gear and tires with Hypertech module
   • Changed the starter battery to 27F X2Power AGM battery (dual purpose 92 AH deep cycle with 930 CCA) to run winch and house (tested heavily, works excellently).
   • I did all of the work myself in my garage, with exception of the alignment, exhaust reroute welding, and I bought ECGS re-built cores (did not spec the third members myself).
   • All bolts were torqued to factory spec, often security sealed, and cleaned before reassembly.

The end! Thank you all again for the valuable threads that helped make research and part selections easier than ever before. And, thank you, TacomaWorld for providing a great platform for us all to discuss the intricacies of the great Toyota platform.

 

Wait, the end? Everyone knows a build never ends..

Nice to see another 09-11 white AC build. Looking good!

 

@fatfurious2 I needed a little ba-dum(!) drum symbol after my "the end" ... it's definitely a never-ending process. Your '10 looks GREAT.

 

my "build" has slowed way down, but yet I still find myself buying parts, and hoarding them (on my shelf/basement I have a FJ tcase, aluminum radiator, Marlin LCA reinforcements, DRT cab mount relocation, new wheel bearings/hubs with extended lugs, new drums/shoes, WARFAB tierod protection... just to name a few). Plus Im trying to build a storage box for my GFC.

But my new hobby has taken over, and the truck sits or gets daily driven for the most part. Im ok with it. I will get back to her eventually

 

Really nice write up and tasteful build…thanks for taking the time to share everything you have done!

 

@fatfurious2 I hear you on the hoarding parts method -- I've been doing the same, and finally have most of what I bought attached to the truck. Your new mods planned look like great ones, especially that FJ t-case swap. The T-Case and cam tabs are definitely on my mind, too.

@Road_Warrior Thanks for reading! Park your truck next to mine, and I think we would look a bit like Star Wars characters. Unfortunately, I think that makes me a Stormtrooper, which doesn't bode well for me... haha

 

Hey at least they both look good!