1996 Tacoma Chassis Restoration and Build

Here is my 96 Tacoma that was given to me by a family member that bought it new. It's a V6 extended cab 4x4 auto with 172k on it. It was a "spare" vehicle for them for many years and is in need of some love. Overall plans are fairly mild:

Frame:

-Repair the rust on the right rear frame rail, Install safety caps on the right side rail.
-Descale frame, Corroseal, Paint Frame, Fluid Film inside of Frame.

Suspension:

-I ordered the OME Kit from Wheelers Offroad on Black Friday, w/ 882 front springs, no ael.
-SPC Upper Control Arms, Transfer Case Drop, Extended Stainless Lines.
- Goal is to run 255/85/16 BFG KM3's on an SCS Ray 10 in Dark Bronze.
- Since I am going through the chassis, I am replacing the brake lines w/(nickel coated copper)
-Ditching the LSPV and going with rear disc brake conversion kit w/ an underhood proportioning valve. (stock rear brakes are done and so are the backing plates.) I have done the rear disc conversion on 2 other toyotas that I currently have with great results.
- Also, I have a complete e-locker rear axle I am going to swap in while doing the lift kit. I ordered a harness from Low Range.

Engine:

I am going to do the typical maintenance needed. It had a timing belt and water pump done at 110k which was roughly 10 years ago. I plan to just start fresh and replace these items while I am at it.

Body:

Exterior of the body is clean. It has one spot of rust on the lower left bedside which I will cut out and repair / Blend paint below body line.

Interior is also pretty clean. It does have a water leak on the passenger side. I fixed one of the main leaks but it is still leaking from the wiper cowl. I stuck a bore scope up behind the dash and verified this. I plan to just address it like in the TSB toyota had for these trucks.

I will update this as I go. .

 

Bed Removal on these trucks is pretty easy normally. The two rear bolts (what was left of them took a few extra minutes) to get off.

 

Had some time to go over the rear of the frame better with a wire brush, needle scaler, and a hammer. Main issues are at the rear shock mount and the leaf spring mount. Welcome to the northeast..

 

The bagged grey one is beautiful!

 

Following along ... my dream project

 

Since I plan to use safety caps on the right side rail, I still want good metal underneath the caps. Also, 11 gauge sheet is the same
Thickness as the frame. So I got to work cutting out all the junk. .

 

I am pretty impressed with the quality of the safety caps and how they fit. It’s definitely will make this job much easier. It’s been a while since I’ve ran my mig welder so getting some time on that again is nice. It’s taken a back seat since I got my tig a couple years back. Here’s the last part of the rotted frame. Once I removed this and blew the frame out (compressed air) it’s actually very clean inside which was a relief to see. This is where I finished up this past weekend. I still need to weld the safety cap under the cab but the leaf spring section is finished welded as well. I am awaiting my lift kit still but hope it will come along with the other parts this week.

 

This weekend very little progress was made. Some of the parts have showed up including the rear disc brake setup, brake lines, and some factory rear axle bearings and seals. I got a call on friday that my lift kit from Wheelers was shipping out. I should see that late this week.

I did get the rear axle pulled out, exhaust out, and I have the front bolts on the gas tank sitting in Kroil now. Hopefully they wont break. So far I have only had one bolt break on the entire project so far. I should be able to get out in the garage this week between hanging out with my newborn son to get the tank dropped and the 2 rear cross members out. I have a glass bead cabinet that I will blast them in and some of the smaller parts that need to be cleaned up.

 

Nice work!

 

I’d be careful with that company, I did the same thing and they sent the wrong parts. Worst company I have ever dealt with. You pay for what you get. They sent me the wrong parts for my truck and you’re going to need to source a rear BPV relocation valve for safe operation of the truck, as their kit is missing that. I wouldn’t contact any of their techs either, they have no idea what they are talking about. Toytec sells a complete kit. A complete write up on my experience with the thieves at Wheeler’s Off-road is in my signature

also, I have OEM prerunner rims for sale if you’re interested

 

I appreciate the insight. They have been in communication with me over the course of waiting for the parts, so I cant complain about that. The parts will be here on Wednesday from Wheelers so we shall see.

As far as rear brakes, I am deleting all that mess and going with a rear disc conversion and mounting an aftermarket proportioning valve under the hood.

 

Not much exciting progress made this past weekend on the truck. Got the fuel tank out, the rear cross members removed and glass beaded. Found a small rust spot on the left frame rail above the front leaf spring mount that was covered by the parking brake cable. While this was unexpected, I went ahead and ordered Safe T Caps for the left side rail as well. Might as well do it all now and never have to mess with it again. Those are supposed to arrive today or tomorrow (Fingers Crossed)

So parts are finally starting to show up. Got my lift kit and wheels in this week so far.

 

Few updates. I got the both rear rails all cleaned up and got the safe t caps welded in.

 

I have heard great things over the years about Corroseal and never really had a truck that was in need of it...until I got this truck. It was the perfect experiment. I had some time last night to brush it on the rear rails.

I am using some east wood products on the safe t cap metal as well as a satin chassis black over the whole frame once the Corroseal is good.

 

Nice work, the frame is looking good! I need to learn how to weld

 

This would be a good project to learn how to weld on. I am enjoying it because it doesn't have to be perfect like I try and make my other trucks.

Hopefully within the next week or so I will start reinstalling everything on the back side of the frame.

 

A skill that comes in handy especially when you're a Tacoma owner in the northeast haha. I plan to keep mine forever so I'm guessing it will need something welded up in the future.

Can't wait to see how your truck turns out it's gonna look nice alongside the others!

 

O

You got that right. The northeast is definitely tough on vehicles. I probably wont drive this in the salt and snow which will keep it around longer. I have a Ford Explorer I daily to work and in the winter time I drive it through a touch-less car-wash weekly because it has a excellent undercarriage sprayer!

Thanks man, I am looking forward to getting this thing out in the spring time. Probably camp down at Assateague Island and hopefully a few PA State Forest adventures to start off.

 

I'm in the same boat, glad to see you liked the Safe-t-cap things. I bought the ones to fix my rig, now I just need to pull the ol girl apart and get welding

 

It was the best option next to a frame swap. I think with the right care it should last a long time.