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My 2006 "Adventure Tacoma" build...

Discussion in '2nd Gen. Builds (2005-2015)' started by Olavity13, Feb 22, 2012.

  1. Feb 22, 2012 at 10:25 PM
    #1
    Olavity13

    Olavity13 [OP] Member

    Joined:
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    First Name:
    Ollie
    Rio Rancho
    Vehicle:
    2006 DCLB 4x4 Sport
    Revtek lift, hand built bed rack, Demello Offroad bumper.
    Hello all, been reading here on TW for some time just waiting to get a Tacoma of my own. Finally got one at the right price and got right to it. Some history on the truck. It's a 2006 Tacoma DCLB 4x4 Sport pkg. Already had a Revtek spacer lift installed. One of my main uses for this truck is to take a few friends on long road trips to go camping/fishing/exploring. So I wanted to make a bed rack to accommodate my roof top tent. I came up with a drawing on Gimp with help from a side view pic of Kenny650s' tacoma since I didn't have my truck yet at the time, (hope that's ok). I added the things I want on the truck: Demello bumper, custom bed rack, Rtt, and a wind fairing to help me think it'll help with mpg. Here's the goal: This is not a truck of mine, just a photoshop image.
    TacomaGoal1-1_f4ce51986faead71f56bdc67db7c344bf919e139.jpg
    So first things first, this is a pic of the ad I found of the truck since I didn't take a decent pic of when I first bought it.
    MyTacoma_666ae93db77ca6fe978e9000d5eaeff2d50fcb21.jpg
    I guess the first mod I did was removed the checkered go fast decals. Looks much cleaner.
    The start of the bed rack. Went to the local steel place to get my estimated materials. 50' of .120 wall 1 3/4" tubing and 20' of 3x3" angle steel.
    0204021230_79c593f51ce1f5c3eab35c92e40f68b750c11969.jpg
    First step, make the base. Cutting the angle steel in half, I measured how long the verticle portion will be and cut where the bed isn't straight with a plasma cutter.
    bedrail_a8ee6bab9cc68d4f43ffbe3247265e3c1f355a73.jpg
    Then marked and cut the shape of the bed rails for a clean look.
    bedrail2_8180ce89360f3cd37d7dc4c3ec1522f70c04591a.jpg
    bedrail1_17a3d6660cec8d2c5f858584817fd50ef42b10f7.jpg
    The side bed storage pockets contacted the base material just a hair, so I notched the base to clear.
    bedrailside_52d63add71a8841856c3bb401679e69e8b9bca38.jpg
    The base is bolted down utilizing the torx bolts that hold the tie down rails. The rails will not be sacrificed, simply bolt them over the base.
    I have a pro tools 105 bender at work and got permission to mount it on the alignment rack. Making the first bend. (Sorry, all pics taken with a pre- smartphone camera)0206021526_24b4e7165fb77e9063a268864c24abd245636c6c.jpg
    Being a rookie to the bender, when it came for the second bend for the front/main hoop, we bent the tube in the wrong spot. Should have inserted the tube the other way:rolleyes: To minimize the waste of material, I decided to just cut the first bend at the half way point in the middle and simply make a duplicate bend and weld them together. My coworker brought by his TIG welder to stitch it together.
    0207021628_b6bad5923f7373f377b4ccfd261e0841507bb5ec.jpg
    0207021628a_b5198c5280a64c7dd5b07b276f01bde12d6d31ac.jpg
    0207021630_e6248d679f81ded4a56dfc62c36bcf65fe360e59.jpg
    After checking the fitment and level of the main hoop, we made a plate for the legs of the hoop and welded them on. Placed it on the base and drilled holes through both the plate and base. Then welding nuts on the underside of the base to be able to quickly bolt the rack on without having to fight the base and remove the rails.
    0207021657_650c8f7c1871e1e51ccda118b7b363b29224de0b.jpg
    0207021659_6e7c9d2dc7efc66d4a9349b859d75182f6244e8c.jpg
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    0207021829a_4f20bee90e3e1a0bfd0e7cd8ed69c0187179f52b.jpg
     
    Mountaineers11 likes this.
  2. Feb 22, 2012 at 10:57 PM
    #2
    Olavity13

    Olavity13 [OP] Member

    Joined:
    Feb 22, 2012
    Member:
    #73408
    Messages:
    9
    Gender:
    Male
    First Name:
    Ollie
    Rio Rancho
    Vehicle:
    2006 DCLB 4x4 Sport
    Revtek lift, hand built bed rack, Demello Offroad bumper.
    Since the bender was already setup, I made the bends for the rear hoops to get ready to cut and weld on.
    0206021724a_fdde1930cb6514f208dc47358057e93cbd6450fa.jpg
    After holding the rear hoops up to mark for the correct height, I used my harbor freight protractor/angle tool to mark my leg to cut parallel to the base.
    0208021456_3e6808144fdc603fedf0402620b8bffa5bc01495.jpg
    Its good to have a coworker who fabricated turbo kits prior to working here with me. He happened to have a tube notcher and portaband saw lying around at the house.
    0208021544_d8df04ad7749de23311113dcea9bab2032137b17.jpg
    Made base plates for the legs and drilled them ready to be bolted in. One rear hoop tacked in place.
    0208021738a_7ac7b30d9c50eae3b39daf5d52cc975a663b72e8.jpg
    0208021737_04514d9686a741b2841532d165a99d0d3f8b15b0.jpg
    And both in place.
    0209021331_e256ee26cef43d3fb2c1120c2f5c63436dc6e66e.jpg
    0209021803_d8da13f093db7320df12a7ab1fc1e590af7412d0.jpg
    This pic appears the rack is getting taller towards the rear, but I assure you, its an illusion.
    Once the rear hoops were tacked in place, it was time for cross bars. The steel place ended up giving us one 10' section that was just larger than the rest and luckily it worked out perfect for the job.
    0209021331b_0b3d25221b74ce7bd104cf925342addc610b83b5.jpg
    0209021331a_01ffc6e53ed54a7fc598c238e412727781c3f12f.jpg
    0209021342_bb450a8ea18b7b45f9c706f30ae5919b453e6766.jpg
    After all was confident it was square, we tacked it up and took it off for complete welding.
    0209021644_9e89e67af27a75d9f71aacb98231e8ee68b590a2.jpg
    0209021644a_83ba3c4b8c443d42d28c43891d70a47c8e85f151.jpg
    0209021644b_ebb0ad07d4356d109116b2c57618ddcab718e82e.jpg
    0209021615a_d11da0cdb4101d52dd161e7839b6a87d9079cd5e.jpg
    0209021615_940694cbc163b31c6e61e2c4942e65a4c0221444.jpg
    Almost finished!
    0209021804b_1c622339537bfd181dd3a5b88aa2a46b43571ad5.jpg
    0209021804a_8fb96eb2c81c48b88a61ae0382f741b0eaddf539.jpg
    I decided I wanted additional tiedown locations so I used a hole saw on flat plate and cut to fit the corners and welded them in.
    0210021626_05b68bfee1b334e02308d9269e910e4bb82755a0.jpg
    0210021626a_14bed1941b0878c25efa65eaa1a88bbd92456101.jpg
    0210021808a_d9cbe9f3d3203c796dc1c32b99923ad6ce800ff8.jpg
    0210021809_b164443d9f8a1004fa43c1458dc747e3e5425e5c.jpg
     
  3. Feb 22, 2012 at 11:17 PM
    #3
    Forster46

    Forster46 Very nice how much?

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    6000k HID's, AUX Reverse Lights, 3" Rough Country Suspension Lift, Pioneer AVH-P4200 Double Din, Underglow and footwell Lights, Camo Seat Covers, Duralast Tool Box, Blacked Out Badges, Grill, Front Emblem, Midland CB Radio, Amber Strobes, POWER REAR WINDOW, cup holder LED's, Firestik 3' in bed, console divider, Ultragauge.
    This rack is awesome man. Did you just start it?
     
  4. Feb 22, 2012 at 11:18 PM
    #4
    Papa Tac

    Papa Tac Adjunct Anarchist

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    '10 Ned Ludd Edition
    Pupped my ride - Dog bench, Black stock rims, Tail Gate antitheft mod, Bed storage and sleeping platform, Action Cap w/Yakima rack and Rola basket, Seatbelt chime off, Tentasaurus
    Mmmm, that's nice
    Great work, man!
     
  5. Feb 22, 2012 at 11:22 PM
    #5
    S7ICKlVlAN

    S7ICKlVlAN Cpt. Bubbleguts

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    Nice fab work and welds bro!
     
  6. Feb 22, 2012 at 11:23 PM
    #6
    rleeharris

    rleeharris "Old Timer," compliments of 11Taco2.7

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    Looking awesome so far! Kudos, Sir.
     
  7. Feb 22, 2012 at 11:29 PM
    #7
    Olavity13

    Olavity13 [OP] Member

    Joined:
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    Messages:
    9
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    Male
    First Name:
    Ollie
    Rio Rancho
    Vehicle:
    2006 DCLB 4x4 Sport
    Revtek lift, hand built bed rack, Demello Offroad bumper.
    I was thinking of other things I could possibly want on the rack before I gave it a final paint/liner finish. So I then thought about a place to mount lights.
    Found the perfect steel channel at home depot for under $10 and started cutting. Ended up making a total of eight tabs.
    0214021807_fc180a5db456105ac92da8ea056cf10ef6a83af8.jpg
    Used a belt sander to shape the tab to fit the tubing nicer.
    0214021806_51767093de711a6228f2199a21c843791d0c462f.jpg
    I decided to locate four tabs on the front main hoop and two tabs on each rear hoops.
    0216021820_bf8d328dbd453d0b2689202c10e080a607f0321a.jpg
    0216021823_7b8ee3b046de6b6feb487b93b822ce3105b5a442.jpg
    0216021820a_45a65c19e96879893e2288981439bfde463ad184.jpg
    I have four HID offroad lights on order through my dealership and will mount on the front tabs. I plan to drill just behind the tabs for hidden wire routing through the hoop.
    Got bored looking and researching for the best finish for the rack and decided the rack needed some handles in the back.
    Started with a 3/4" tube I also found at home depot. My coworker also had a small woodward fab tube bender lying around and made a bend to see how it would look.
    0218021238_816ce1f2dfb4ebd8f119306ea17dfdae36f8c560.jpg
    Tack welded and turned out better than I had expected.
    0218021239_66145385efc3e106c213ae936f0fe30590303daf.jpg
    0218021239a_44f9b44cef1504041a32e0b23465bde749ad7178.jpg
    Welded them both in place and smoothed out to prevent any chance of injury.
    0218021354a_0cbfca4d3ac077516dd86e9a6836d544b8b20d29.jpg
    Used part of my tax return to buy a Demello bumper.I really like the look of the three hoop version so in an effort to save money I ordered it without a coating and no hoops.
    0221020913_ae73fd88b3c06bbc96045a28435cb1cfbf6cd8c7.jpg
    This thing is beefy and fit perfectly without a fight. Didn't install the other brackets in order to save the hassle of taking it all off to paint it once the hoops are done.
    Bent some of the remaining tubing for the center hoop of the bumper.
    0221021637_ca118e301960d87666e667cc95ebdf6afc44a1c4.jpg
    Tacked in place.
    0221021736_fa8139575dd29c02386832dd566db4f47c8372d6.jpg
    The center hoop sticks out further than the pictures I have seen, but I like the look.
    0221021735a_5a5a7da8908e3bfa65fc2316cae13b67410347df.jpg
    Next was the outer hoops. Bent and cut to fit where I liked it.
    0222021723a_aeb5d33b5f1a2680d5a87e3462a8135fb7c54cdb.jpg
    0222021723b_62aa7da1b5e1f1ce0dd50d400c78a8c6c8d7940e.jpg
    0222021723_a6bace3c091b4c302b204f6049bf6f243888c2a6.jpg
    And that's where the build is for the time being. The time it took to build the rack and bumper hoops was about two weeks time in our spare time. Luckily/unfortunately It was slow at work for the most part so I had alot of spare time the last two weeks.
     
  8. Feb 22, 2012 at 11:47 PM
    #8
    surferkid

    surferkid Zombie Killer

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    that is awesome man! you are a master fabricator those welds are clean!
     
  9. Feb 22, 2012 at 11:53 PM
    #9
    Krazie Sj

    Krazie Sj Resident Jackass

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    This is an impressive build. Max Kudos.
     
  10. Feb 23, 2012 at 12:02 AM
    #10
    Twistedfreedom

    Twistedfreedom welcome to the incredibuild

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    modded the F*ck out
    These are the best three posts I've ever seen
     
  11. Feb 23, 2012 at 12:17 PM
    #11
    Olavity13

    Olavity13 [OP] Member

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    Ollie
    Rio Rancho
    Vehicle:
    2006 DCLB 4x4 Sport
    Revtek lift, hand built bed rack, Demello Offroad bumper.
    Thanks. Started it at the beginning of this month.

    That is awesome.
    Thanks for all the kind words, I hope to finish the outer hoops today. We'll see.
     
  12. Feb 23, 2012 at 8:36 PM
    #12
    Forster46

    Forster46 Very nice how much?

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    Where do you work?
     
  13. Feb 23, 2012 at 9:02 PM
    #13
    griffin407c

    griffin407c Well-Known Member

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    i like it. good job
     
  14. Feb 23, 2012 at 9:04 PM
    #14
    Bengland25

    Bengland25 Never Forget! 343

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    That rack is awesome man! looks really good! You should start selling these things, i bet a lot of guys would love to get this!!
     
  15. Feb 23, 2012 at 9:08 PM
    #15
    sytfu510

    sytfu510 INSTAGRAM: sytfu510

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    judging by the uniforms, Honda.

    Great work OP! looking forward to seeing the finished product.
     
  16. Feb 23, 2012 at 9:09 PM
    #16
    Rupp1

    Rupp1 "If you can dodge a wrench, you can dodge a ball."

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    Like it! :thumbsup:
     
  17. Feb 23, 2012 at 9:10 PM
    #17
    ItalynStylion

    ItalynStylion Sounds Gooooood

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    Excellent work! Keep 'em coming!
     
  18. Feb 23, 2012 at 9:30 PM
    #18
    berg2065

    berg2065 Well-Known Member

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    congrats on your new tacoma and can't wait to see this build progress. Nice work OP.
     
  19. Feb 23, 2012 at 10:36 PM
    #19
    Leer

    Leer Well-Known Member

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    Just....WOW!
     
  20. Feb 24, 2012 at 8:54 AM
    #20
    Olavity13

    Olavity13 [OP] Member

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    Ollie
    Rio Rancho
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    2006 DCLB 4x4 Sport
    Revtek lift, hand built bed rack, Demello Offroad bumper.
    sytfu510 got it right. I work at a Honda dealership.
     
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