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02 Double Cab Build

Discussion in '1st Gen. Builds (1995-2004)' started by whitetoblack, Mar 13, 2012.

  1. Mar 13, 2012 at 3:21 AM
    #1
    whitetoblack

    whitetoblack [OP] ******

    Joined:
    Feb 23, 2010
    Member:
    #31986
    Messages:
    1,101
    Gender:
    Male
    First Name:
    Tyler
    SoCal
    Vehicle:
    02 Prerunner & 08 Prerunner
    Johnny Branch Fabrication, King, Deaver, Glassworks, Toyo Tire, Alpine, work in progress...
    http://youtu.be/6thim3EY9Dg

    http://youtu.be/g3Oufhv3Q0s

    http://youtu.be/pPR27HfoC6c

    Modifications:

    Cosmetic:
    Fiberwerx 1 Piece 2nd Gen Conversion Clip
    Glassworks 6" Bedsides w/LED taillights
    Front and Rear tube bumpers
    3 LED Rear Light Box
    Vinyl Flooring
    180W LED Light Bar
    240W LED Roof Bar
    Snugtop Camper Shell

    Front Suspension: Bumped/Strapped 16" travel
    Custom 6.5 over kit built by Johnny Branch
    2.5x10" King Dual Rate Coilovers
    2.0x2.5" King Hydraulic Bump Stops
    Upper arm gussets
    Plated coil bucket and frame
    Plated and tubed shock hoops with Engine Cage
    Solid mounted Lower Arms/Heimed Upper Arms
    Solid Motor Mounts
    Solid/Boxed Transmission Mount

    Rear Suspension: Bumped/Strapped 18.5" of travel
    Giant 64" Link Killer Kit
    King 2.5"x16" Triple Bypasses
    Tundra Axle
    Frame Plating
    All fabrication done by EJV Fab

    Stereo:
    Jensen 7" head unit
    Alpine Type R door speakers
    600 watt Alpine 4 channel amp
    Alpine Type R 10" Sub
    1500 wattt Alpine monochannel amp

    Wheels and Tires:
    MB Motorsports Machined Aluminum Rims 17"x9"
    Toyo Open Country MT 35"x12.5"

    Next purchases:
    Internal Roll Cage

    Well been on this site for a while now never thought to do a build thread but here it goes. The truck has changed tremendously since I bought it, for better or worse depending on your style. Bought it back in April 2009 with 105k miles on the v6. Had a Fabtech lift kit with the coils cranked all the way, add a leaf in the rear, 17" Helo rims, 33x12.5 Durango Radial XTRs, Jensen Head Unit, and a blown stock sound system. Heres how she looked the day i got her.
    truk10_89c7622d050d068509ef5ea7f0856e23e3bf6ee6.jpg
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    First off, the blown speakers were a critical part to replace. Instead of replacing them with new stock components, i decided to go with alpine Type R door speakers, a 4 channel 600 watt amp for the speakers, a 10 inch Alpine Type R Sub with a 1000 watt amp to power it. Ended up spending just under $1000 and was very happy with the way it works, very loud and extremely clear and crisp sound. I personally wasnt a big fan of the Helo rims and Durango tires, so I posted them for trade and traded straight across for a set of 15" Pro Comp Streetlocks and 31x10.5 BFG All Terrains.

    frontt_2dcedfbaa2022abb3ea93a1ced4030448292ad2f.jpg

    After throwing on the wheels and tires, i realized the 31s were not big enough. So, when they wore down after a few months, I bought a set of 33x10.5 All Terrains.

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    As i started to run my truck more and more in the dirt, I realized that I was becoming more concerned with how well my truck rode. The first thing i did was swap out the Fabtech's with some Icon Coilovers and I was extremely satisfied with the improvement. The truck sat about and inch and a half lower but the ride was improved 100x.

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    Next step was trying to get the rear up to speed. I picked up a set of Deaver j59s from a friend of mine. Even before swapping out shocks, I had already noticed another night and day difference in ride quality. At that point, another friend of mine was selling a set of 2.5x8" King Smooth Bodies with Remote Resi's for a price I could not turn down. I bought them and installed them with my Deavers.

    kings_97555f89dcae3ff401ffaa8af5cb1809a9caf004.jpg
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    I was extremely satisfied with the ride quality on and offroad. At that point, I began piecing different things together that I thought added to the looks as well as improving different aspects of the truck. A friend of mine had been building bumpers for a number of people so I decided to have him build me a rear bumper. I was extremely satisfied with the results...

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    At around the same time, I picked up a Defiant Light Bar and 2 ProComp 9" lights...

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    Ran it like this for quite a while and was extremely happy. Then, as I continued to run it harder, I lost control in the dirt on my bald BFG's and crashed. The damage was limited to a dented hood, mangled bumper and light bar, broken grill, and dented core support...

    20101012093339_aa7595a18ac42222abc2ffc8e1e32481907d9dbc.jpg
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    After that incident, I realized it was definitely time for new tires. Luckily, General had just released the Grabber Red Labels a couple weeks before and I picked up a set for an incredible deal.

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    At this point, after taking my truck to the desert a number of times with it's current set up but not being able to keep up with all my friends rangers and such, I began saving for a new front end. While I was saving, I came across a set of brand new Glassworks Fenders for only $125 so I jumped at the deal and picked them up...

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    Also picked up a dust light in the meantime...

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    Decided to try a slightly different look that I had not seen before so i painted the rear fender flares white. I liked the way it turned out so they are staying that way for a while...

    20110317162104_67ae615a83aa0b4fdb670f42ffa16cc09ab28920.jpg
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    After months of driving with a busted core support and hood, I finally saved up enough coin to get it all fixed. And now, this is how she sits...in my garage ready to get a full makeover.

    20120312170629_6c5f710dbec7da6a7d56f1581de261b5591f0b01.jpg

    Picked up a long travel kit used on dezertrangers and some 2.5x10" Kings from a friend the real build begins.

    20120328142857_9203bf34b788cbd2d906ff2ffec5078d62038d8e.jpg
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    Added a couple more gussets to the coilbucket and shock mounts. Still gotta do a little more plating and run the tubes to the frame and over the engine.

    20120404125453_ba646492f32b8df75ce30da99c40f80d30742f42.jpg
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    Bumper Started as well as resi’s mounted

    20120416144752_4a81d3e833e6969b37687212cf0fb3050ef80c73.jpg
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    Bumper finished
    20120503151826_2347860a2de552b5fb6e0fba3a1e2bb97e327379.jpg
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    Mounted my license plate and light on a hinge to reveal the tow hitch easily
    20120526073937_0ff9e1c83d055f50e5bd81b91cbb3cbdeca36458.jpg
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    Picked up some glassworks bedsides with the taillights section filled in ready for oval LEDs.
    2012-06-20_18-46-09_705_70a8457cf546fca2c7a61cbf731e8f2de29dd308.jpg
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    Plated the backside of the shock tower and put a removable hoop over the motor.
    photobucket-7092-1344484379970_729fa7257e543dd2d82aa498eb446fb05b696196.jpg
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    To be continued.....
     
    Last edited: Jul 20, 2017
    Dalandser and LBCDUBCAB01 like this.
  2. Mar 13, 2012 at 3:24 AM
    #2
    chaz834

    chaz834 Tacoma 4 Life.

    Joined:
    Nov 10, 2010
    Member:
    #45986
    Messages:
    1,414
    Gender:
    Male
    First Name:
    Chase
    Kendrick, Idaho
    Vehicle:
    2012 Sport MGM
    3'' Tuff Counrty Lift, Moromoto Mini H1 Projectors 5000K 35W, BHLM, 30'' LED Light Bar, Black TOYOTA Emblem, Excelon Touch Screen Deck, Hertz Speakers,Excelon AMP, 2 10'' JL Audio Subs, Wet Okle seat covers, Weather Tech Floor Mats.
    Nice pickup man!!
     
  3. Mar 13, 2012 at 12:32 PM
    #3
    travis9287

    travis9287 Roll Tide!

    Joined:
    Jun 1, 2010
    Member:
    #38150
    Messages:
    1,637
    Gender:
    Male
    First Name:
    Travis
    Sylacauga, Alabama
    Vehicle:
    Big ol POS
    Allpro APEX, 255's t4r wheels, Custom Rear Bumper.
    Looks good man!
     
  4. Mar 13, 2012 at 1:17 PM
    #4
    AlphaEcho2k5

    AlphaEcho2k5 Well-Known Member

    Joined:
    Mar 2, 2011
    Member:
    #52220
    Messages:
    1,833
    Gender:
    Male
    First Name:
    Adam
    F.E. Warren AFB, WY
    Vehicle:
    '02 4Runner
    Awesome Runner!
     
  5. Mar 13, 2012 at 2:29 PM
    #5
    01Tac0ma

    01Tac0ma Bash Fabriction & Off-Road

    Joined:
    Jun 11, 2010
    Member:
    #38782
    Messages:
    6,259
    Gender:
    Male
    First Name:
    Chad
    West Columbia, SC
    Vehicle:
    SAS 01 TRD 4x4
    Look at build!
    I like it! Nice job...what do you plan on doing for the front bumper?
     
  6. Mar 13, 2012 at 2:52 PM
    #6
    Tacomadude89

    Tacomadude89 Well-Known Member

    Joined:
    Feb 6, 2010
    Member:
    #30859
    Messages:
    1,498
    Gender:
    Male
    First Name:
    Austen
    California
    Vehicle:
    2002 Tacoma TRD SR5, 3.4, 5spd
    -Bilstein 5100 Series shocks on all 4 corners -Rancho HD lift coils -1/4" Toytec driverside top plate spacer -Toytec 1" diff drop -Wheelers 1.5" AAL's -Toytec 1" lift shackles -Revtek extended length BPV bracket -285/75/16 BFG KO T/A's -Pro Comp rims -ET Conical tyle lug nuts -Spidertrax 1.5" wheel Spacers -CV Boot slide mod -TRD skid plate -Magnaflow 14" round muffler -Shortened tailpipe hidden behind framerail -Toyota bug deflector -Weathertech floormats -Black leather seat covers -Valentine 1 Radar Detector
    Sick truck!
     
  7. Mar 13, 2012 at 6:44 PM
    #7
    tacotrd647

    tacotrd647 Resident "dude"

    Joined:
    May 29, 2011
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    #57421
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    First Name:
    Caleb
    Ridgeway, Iowa
    Vehicle:
    02 Prerunner SR5 TRD
    KMC Enduro Wheels, 265/75/16 toyo open country at2
    What size are the grabbers? Sick truck!!
     
  8. Mar 13, 2012 at 7:30 PM
    #8
    whitetoblack

    whitetoblack [OP] ******

    Joined:
    Feb 23, 2010
    Member:
    #31986
    Messages:
    1,101
    Gender:
    Male
    First Name:
    Tyler
    SoCal
    Vehicle:
    02 Prerunner & 08 Prerunner
    Johnny Branch Fabrication, King, Deaver, Glassworks, Toyo Tire, Alpine, work in progress...
    Picked up some vinyl flooring to replace the old shitty stock carpet.
    photobucket-8312-1348164619193_zpsdf8af8_87eb506f6231f345a83d71acea9848ed71dc8022.jpg
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    Next I got some 17x9 machined aluminum wheels to clear the Tundra axle along with some 35x12.5 Grabber SCTs.
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    Threw a 32” LED light bar on the bumper.
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    Installed some 2.0x2.5" stroke King Bump Stops

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    Picked up Giant 64" Kit.

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    Before
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    After
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    Bump
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    Extra Pics and gussets

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    photobucket-22604-1360128253581_zps0fb03_a899b91d53d872f4cf606b13d57cfc6d102791ba.jpg

    Next was the bedcage

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    2013-02-08_15-15-41_931_zpsb4857a28_e30f331801b7cb49c953097ea95450e0d994da8a.jpg

    Took the truck out for its shakedown run and it works awesome! Had a few expected issues but nothing with the suspension or fab work.

    2013-03-05_11-36-58_483_zps2fd6efa5_8362f7e3b5e238186d340c37be42e4280ee7b3cd.jpg

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    Ran it through a pretty rough section of the race course and it floated awesome over some 3-4 foot whoops and a couple heavy g-outs. Started hearing a clunk up front so we stopped and looked. One of the light bar bolts had shaken out and caused the bar to bounce and shear off the aluminum mounting bracket. The light itself was in good shape still so we yanked it off and pulled the corner lights out and continued on.

    2013-03-02_12-17-37_678_zpsa2693e84_e15ffb9a6da7d5d9a98adf3e69d1a71b59027d18.jpg

    2013-03-02_12-17-46_447_zpsf6222d15_0e53fb12f37d7a501f31d279af697620149d8380.jpg

    Got a bunch more runs in and pulled off to check the bolts and everything was working great. The truck pulls through the whoops awesome without shuffling side to side at all.

    Screenshots952013-03-02-16-52-16_zps11b2_af81961a42d01687f56ff3eddfe2dff21b9f846e.jpg

    securedownload-4_zps176ff02c_44bec8fa897aa1183973f155666e695494554149.jpg

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    After that we made our way back towards the highway and hit the race course once again. It did awesome in the trenches with the ground clearance of the 35s. Through it up on a rock to check the shock clearance and it has no rubs whatsoever. After running it hard through the biggest stuff out there, we did a final check and found the stock steering rack bushings had blown out. Also, as expected the alignment cams had been knocked out of whack because they were not tacked. On top of that the driver side motor mount is blown.


    2013-03-02_14-23-32_646_zpsf6f3195f_d5c01b92e578b0bd4cfd7f908825f7f8e5ddb28f.jpg

    2013-03-02_14-24-24_341_zps01b6ab8c_43b1e430bc825463db1569c937efc9f807587e2e.jpg


    All in all it was an awesome shakedown. The frame did not flex like it used to and everything felt sturdy. Did not touch bump once in the rear!



    First thing I did when I got back was install poly bushings on the steering rack. It is an upgrade I would recommend to everyone. It made my steering feel a lot tighter and noticeably more responsive.

    Next step was to heim the upper arms to get rid of the weak stock alignment cams.

    2013-03-18_14-17-44_844_zpse8d0ecf7_52a5f80a728101171e20fd1c6f38ed9fa5191404.jpg

    2013-03-18_15-55-52_539_zps699bb71f_39340e30a594c2a5d96737eb140ba7d3f36f1c5f.jpg

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    2013031995185946_zpsad5cb07c_5e878a1cfe07823970a1b28cb8800b0b128cc207.jpg

    The final step in addressing all the issues from the shakedown was solid motor mounts and boxed frame perches.

    Old motor mount

    2013-03-28_09-04-38_47_zps0ac7ffcc_d70cbcda42315d9c4aaf1362afd54ba67b72b919.jpg

    New motor mounts

    2013-03-27_19-32-57_309_zps7c35d5d7_aaec8a882bedf71bc77dfd7695b128acf49a9c24.jpg

    2013-03-28_09-59-48_567_zpsecb786b7_4158d17cd203bf958c2389dab0d17da7e356529f.jpg

    Now that it is completely done suspension wise, I have just been driving the heck out of it and enjoying all of the time, cash, and hard work I have put into it.

    2013-03-14_12-20-31_220_zps54ddfb68_092756f3b024d544d49f8c5208b3efc9414b765c.jpg

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    2013-04-03_13-18-58_538_zpsb7122e32_a5593faad23c74d5b08d2535cc1156caecf3758e.jpg

    2013-04-03_13-19-15_710_zps1b6eae18_8e9db368c993e3bb949f83dc5047cfca30034869.jpg

    As mostof you know, it is never really over. At the moment I am saving for the cage and that will most likely be the last step for a long time. Stay tuned

    In the mean time before the cage, we figured might as well put the one piece conversion on. My friend said he wanted to try and mount it all to a sub-frame so that it could swing up and not have to come off everytime I need to do anything under the hood. Here is what he came up with. Extremely impressed with how it turned out considering he had never done this before!

    34gpk0j_zpsd81389f4_42eaca6ec16dddc51f2182fbce14fce96d472ae6.jpg

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    IMG_20130425_162813_860_zps6a32d1e7_200df590553c3bcaa805e3ef099b56f3c358fd48.jpg

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    Last edited: Jul 25, 2013
    Dalandser and TacoShell like this.
  9. Mar 13, 2012 at 10:09 PM
    #9
    Anthony250

    Anthony250 E-Fabber

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    TC Kit, Methods Double Standards, Sway Away, King Shocks. Prp Seats, 35's
    Dont you have a LT kit ready to go on?
     
  10. Mar 13, 2012 at 11:00 PM
    #10
    whitetoblack

    whitetoblack [OP] ******

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    Johnny Branch Fabrication, King, Deaver, Glassworks, Toyo Tire, Alpine, work in progress...
    2013050295100851_zps4ef39a62_955fe8dd1a8debab8ad5f18315520ebe959979c0.jpg

    2013050295095240_zpsad0b3e4f_f80ada13fe6bd7fdf25ca0c68db162153f6c7bae.jpg

    2013050295095157_zpsf3c79531_759289facaabec2e6482286574bfdb2f3b61f5f9.jpg

    2013050295100804_zps5339d5b1_04e866ca4ef32caf52b4cf5a5f1926a11833d971.jpg

    IMG_20130519_134150_411_zps03b00710_7450b92874a6155119e4835fbf29488902d1e21f.jpg

    IMG_20130612_111913_155_zps0dea2d84_59f5e9ca4b63fc67bda3128c5d97d924812c3541.jpg

    Also picked up a mint condition Snugtop Camper Shell

    IMG950885_zps10417de2_2d0c787e8a6a51ebc0306cc5f20c376daf56a087.jpg

    IMG_20130612_184119_376_zps3a31a2f0_b3cbc9a2ca16c52ac24194d80a7ab8ee52472b55.jpg
     
    Last edited: Jul 25, 2013
  11. Mar 14, 2012 at 9:34 PM
    #11
    whitetoblack

    whitetoblack [OP] ******

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    Johnny Branch Fabrication, King, Deaver, Glassworks, Toyo Tire, Alpine, work in progress...
  12. Mar 14, 2012 at 9:36 PM
    #12
    Anthony250

    Anthony250 E-Fabber

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    TC Kit, Methods Double Standards, Sway Away, King Shocks. Prp Seats, 35's
    Your tire is pretty close to that spindle at turn.
     
  13. Mar 14, 2012 at 9:56 PM
    #13
    whitetoblack

    whitetoblack [OP] ******

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    Calipers are not on and the tire is not even fully mounted just two bolts to hold it on. Just trying to get a rough estimate of width. Need to trade the 8s I have for 10s also.
     
  14. Mar 15, 2012 at 12:21 AM
    #14
    Anthony250

    Anthony250 E-Fabber

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    Oh ok Gotcha. What are you doing for rear?
     
  15. Mar 15, 2012 at 1:25 AM
    #15
    whitetoblack

    whitetoblack [OP] ******

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    Still deciding exactly what I want to do but a Tundra axle for sure along with either 62s or possibly a 64 kit with the wider axle. Still deciding. Looks like im gonna be pulling 16" strapped with the front kit so I still gotta choose. Planning on caging it later this year also so might as well go all out. Still a pretty slow step by step process though haha
     
  16. Mar 19, 2012 at 10:12 PM
    #16
    whitetoblack

    whitetoblack [OP] ******

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    No goin back now haha

    20120319205657_3efe2f79bde5d482a5a0abe04cd4fe49535bed79.jpg

    20120319201240_b580a5deca32ea227dfcf7d56dc58c509e2f452f.jpg

    20120319223136_52d21ad11630580457b62e0ebfa99a3ac8a2e587.jpg

    Mocked up the 8 just to make sure I need 10s and sure enough it wouldn't cycle the full 16 where the tab is on the arm. So I am still looking for 10s. Plus I want to be able to run dual rates so it will work out well
     
  17. Mar 19, 2012 at 10:31 PM
    #17
    livel0veryde

    livel0veryde Well-Known Member

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    mid missouri
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    100% stock...ish
    very nice. truck looks sweet man.
     
  18. Mar 28, 2012 at 6:28 PM
    #18
    whitetoblack

    whitetoblack [OP] ******

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    Trucks coming along should be done this weekend. Scored some brand new kings from my buddy yesterday for $600! Got the coilbuckets done, upper arm gussets cut and being welded in tonight as well as the shock hoops. Gotta hand it to my buddies doin all the fab work its coming out even better than I could have expected. Here's a couple pics. Need to pick up that tundra axle quick cuz she sits wiiiide. Also possibly switching to the 2nd gen fiberglass front clip.

    20120328142857_9203bf34b788cbd2d906ff2ffec5078d62038d8e.jpg
    2012-03-2295121947_6b3b5796bfa4e793bfa43eb1a646908168437e94.jpg
    20120328112027_09035a6e5a4e5c199591c9de16e7bd6fe702396a.jpg
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    20120328112217_b42cfcca4b1fa2b067ae50adbe9368a33efe1d29.jpg
     
  19. Mar 30, 2012 at 7:01 PM
    #19
    whitetoblack

    whitetoblack [OP] ******

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    Johnny Branch Fabrication, King, Deaver, Glassworks, Toyo Tire, Alpine, work in progress...
    Got the shock tower up and welded in. Now all it needs is a couple more gussets to the coilbucket and upper mounts, bracing on the sides of the shock tower, resi mounts, and the engine hoop. Also bumper will get started Monday. Plus I still gotta find some top springs for the coilovers.

    20120329225531_0b8f88bea04b9c0cfa413ba4371b3772d368013e.jpg
    20120329225547_2cb3603f1e599e9c307414ff72a2f70e1c4666c0.jpg
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    20120330162454_ff59bc47fa72e1f79aeace520499711597dc5c2a.jpg

    Got some pretty cool ideas for the rear suspension and fiberglass that I haven't seen done before so I will continue to update.
     
  20. Mar 30, 2012 at 7:29 PM
    #20
    tacotrd647

    tacotrd647 Resident "dude"

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    Ridgeway, Iowa
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    KMC Enduro Wheels, 265/75/16 toyo open country at2
    Holy shit, you weren't kidding! That fucker is wiiiiide! Sick build dude, what kit is that on the front?

    Fab work looks amazing..looking forward to more progress!
     
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