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Scott B.'s 2015 AC Build - Expo Style

Discussion in '2nd Gen. Builds (2005-2015)' started by Scott B., Mar 28, 2015.

Page 2 of 16
  1. Apr 20, 2015 at 10:56 AM
    #21
    Scott B.

    #21
    Scott B. [OP] Well-Known Member

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    I have been thinking a lot about the suspension. Specifically, how I want to upgrade/lift the truck. There are quite a few options available!

    I have decided to run a 3” lift instead of a drop-bracket lift. I also like the long-travel setups, and may upgrade to one in a few years. For now, though, a semi-custom (mostly) bolt-on setup is in order.

    Front


    I like the Camburg UCAs with a 1.25” uniball. One decision made.


    For the coilovers, I see 2 groups – Bilstein 6112s or King/Fox/Icon. Given the price difference between the two groups (double) I am trying to decide if I really need the better ones (and, if so, which of the 3 is the one get?)


    Rear


    On my other truck, Deaver built me a custom set of leaf springs (taking into account weight and reversed (tension) shackle configuration). They work great! I am going to have them build me a set for this truck. Another decision made.


    However, there are a couple of lingering questions. Convert to spring under? I’ve seen a couple of trucks that did, and they claim additional suspension travel. Not sure I agree with that. I have a picture (unfortunately, no other info) of a truck with an extended tension shackle. If I can find that setup (or build one) I will run it.


    I plan to run a matching rear shock, but want to change the upper shock mount. Changing to the other style mount (not sure what it is called) will open up the selection of shocks. I want them to be long enough to allow for the droop travel of the new springs. BAMF has a nice extended shock tower. Unfortunately, to get maximum upward extension, the shock must move outboard toward the tire. This will be a problem since I do not to run spacers. So, I think I will build a shock mount, or modify the BAMF ones.

    Drivetrain


    I plan to run 285x75-16 tires on 16x7.5 wheels, 4.56 gears with a TruTrac in each end.



    I am not new to off road travel, but am new to Toyotas. My thoughts/decisions/preferences are from past experience with my other trucks and reading about people’s experience with Tacos. Any thoughts, suggestions and/or comments are welcome.

    One last note – I plan to lift the truck in June. 6 weeks should be enough time to gather parts.
     
    Scott B., Apr 20, 2015
    #21
  2. Apr 26, 2015 at 5:49 PM
    #22
    Scott B.

    #22
    Scott B. [OP] Well-Known Member

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    The deck of the sleeping platform is finished!

    Cubby doors (or hatches):

    sp1.jpg

    The rear part of the deck:

    sp2.jpg

    And starting to fit the carpet:

    sp3.jpg

    I decided to leave the rear part of the deck removable. I do not plan on removing it on a regular basis, but if I ever need to get under the deck for wiring or to fix a drawer, not having 26" of cover will make the job much easier.
     
    Scott B., Apr 26, 2015
    #22
    Crom likes this.
  3. Apr 26, 2015 at 5:52 PM
    #23
    Scott B.

    #23
    Scott B. [OP] Well-Known Member

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    10 HP!

    This mod is easily worth 10 HP!

    Original:

    K1.jpg

    New parts:

    K2.jpg

    A more pleasurable driving experience!

    K3.jpg
     
    Last edited: Jan 9, 2016
    Scott B., Apr 26, 2015
    #23
    Crom likes this.
  4. Apr 26, 2015 at 5:56 PM
    #24
    Scott B.

    #24
    Scott B. [OP] Well-Known Member

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    Tech Deck

    I installed a Tech Deck and Mirror Riser. Both are really nice products.

    Original: (Don't mind the pollen)

    td1.jpg

    Radio out - I didn't realize there were so many connectors!

    td2.jpg

    Backside of radio bezel, about to get the re-enforcement piece epoxied in:

    td3.jpg
    Epoxy done:

    td4.jpg


    Everything back together:

    td5.jpg

    I still need to add the Ram Mount balls - ran out of time today.
     
    Last edited: Jan 9, 2016
    Scott B., Apr 26, 2015
    #24
    Crom likes this.
  5. May 12, 2015 at 2:05 AM
    #25
    DrFunker

    #25
    DrFunker Well-Known Member

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    This mod is easily worth 10 HP!
    :mudding:

    Nice build :thumbsup:
     
    DrFunker, May 12, 2015
    #25
  6. May 12, 2015 at 6:57 AM
    #26
    Scott B.

    #26
    Scott B. [OP] Well-Known Member

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    Thanks.

    More on the way - I have started ordering suspension parts!
     
    Scott B., May 12, 2015
    #26
  7. Jun 1, 2015 at 3:05 PM
    #27
    TRoss

    #27
    TRoss Web Wheeler

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    1.5" 5100 Billie lift, 1.5" AAL w/5125's, 265/75/16 Duratracs on SR8's, ECG diff bushing
    I detect slackage in this thread! Bump! And oh... I'm next for the expo bed mod lol
     
    TRoss, Jun 1, 2015
    #27
  8. Jun 1, 2015 at 3:23 PM
    #28
    ODNAREM

    #28
    ODNAREM MEMBER Of The Church Of @ODNAREM

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    TRD catback exhaust,FJ Cruiser trail team wheels,BFG All Terrain K02 tires,Grillcraft front grill,Pelfreybilt IFS/Mid skids,sliders,standard rear bumper,Total Chaos bed stiffeners.TRD Pro Bilstein front/rear suspension.
    Bed mod looks good OP!Been considering doing this in the future.Hurst shift lever looks real nice!
     
    ODNAREM, Jun 1, 2015
    #28
  9. Jun 1, 2015 at 7:41 PM
    #29
    Scott B.

    #29
    Scott B. [OP] Well-Known Member

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    Definitely slacking this thread - but that is because I have been ordering parts!!!!!!!!

    The lift should be going on by the end of June.

    Oh, and I just sent the rear diff to ECGS for new gears. I will post some pictures once I get it back together.
     
    Scott B., Jun 1, 2015
    #29
  10. Jun 12, 2015 at 12:38 PM
    #30
    Greenbean

    #30
    Greenbean B.S. Goodwrench

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    :popcorn:
     
    Greenbean, Jun 12, 2015
    #30
  11. Jun 20, 2015 at 6:31 PM
    #31
    Scott B.

    #31
    Scott B. [OP] Well-Known Member

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    Getting back to updating this thread:

    Here's a shot of the Tech Deck with Ram Mount balls installed, and my phone holder.

    td.jpg
     
    Scott B., Jun 20, 2015
    #31
    medic2230 and Crom like this.
  12. Jun 20, 2015 at 6:38 PM
    #32
    Scott B.

    #32
    Scott B. [OP] Well-Known Member

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    I did a little debadging...

    Before:

    Before.jpg

    After:

    after.jpg
     
    Scott B., Jun 20, 2015
    #32
  13. Jun 20, 2015 at 6:46 PM
    #33
    Scott B.

    #33
    Scott B. [OP] Well-Known Member

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    Rear Gear, TrueTrac

    So, the other day, I was looking at the truck and had a wrench in my hand.

    Low and behold, look what came out! ;)

    chunk.jpg

    I sent the chunk off to ECGS for a set of 4.56 gears and a TrueTrac.

    chunk2.jpg

    A close-up of the pattern:

    Pattern1.jpg
    Pattern2.jpg
     
    Last edited: Jan 9, 2016
    Scott B., Jun 20, 2015
    #33
    Crom likes this.
  14. Jun 20, 2015 at 10:56 PM
    #34
    Greenbean

    #34
    Greenbean B.S. Goodwrench

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    Sweet!

    Congrats on gears and locker....

    What you doing to the front diff?
     
    Greenbean, Jun 20, 2015
    #34
  15. Jun 21, 2015 at 5:30 AM
    #35
    Scott B.

    #35
    Scott B. [OP] Well-Known Member

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    I would really like to put in another TrueTrac, but they don't make one. :( It is ARB or nothing. Given my plans for the truck, I don't think I really need an ARB, so I am thinking about leaving it open.

    Maybe Eaton will make a TrueTrac one day...
     
    Scott B., Jun 21, 2015
    #35
  16. Jun 21, 2015 at 5:39 AM
    #36
    Scott B.

    #36
    Scott B. [OP] Well-Known Member

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    Gas Tank Skid Plate

    I got a Pelfreybilt aluminum skid plate for the gas tank.

    The SR5 trucks don't come with any skid plates - I thought the gas tank would be a good place to start.

    I decided on aluminum to save weight. This truck is not going rock crawling, so the aluminum should hold up just fine to the projected use/abuse.

    As delivered:

    sp1.jpg
    Since the SR5 did not come with a skid plate, I had to get replacement tank straps that the mounting studs:

    Toyota part numbers:

    77610-04020 - strap
    77602-04020 - strap
    90179-08241 - nut (4 required)

    sp2.jpg
    Before:

    sp3.jpg
    New straps installed:

    sp4.jpg
    Final product:

    sp5.jpg

    It is a well build piece that should last the life of truck.
     
    Last edited: Jan 9, 2016
    Scott B., Jun 21, 2015
    #36
    Crom likes this.
  17. Jun 21, 2015 at 7:23 AM
    #37
    tacoma16

    #37
    tacoma16 Well-Known Member

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    Looking good! Definitely escalated with the wrench and gears eh. Looking forward to see the rest of the truck!
     
    tacoma16, Jun 21, 2015
    #37
  18. Jun 21, 2015 at 6:03 PM
    #38
    TRoss

    #38
    TRoss Web Wheeler

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    Nice! I've been perplexed about running aluminum or steel skids. The weight savings in alloy is very attractive tho.
     
    TRoss, Jun 21, 2015
    #38
  19. Jun 21, 2015 at 6:06 PM
    #39
    Greenbean

    #39
    Greenbean B.S. Goodwrench

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    That looks great and honestly is a VERY smart idea....

    I might be adding that to my truck down the road.
     
    Greenbean, Jun 21, 2015
    #39
  20. Jun 22, 2015 at 6:09 PM
    #40
    Scott B.

    #40
    Scott B. [OP] Well-Known Member

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    Brake Controller

    I added a brake controller since I tow a Little Guy off road teardrop. Besides, the factory already installed a 7-pin connector, so the hard work was done!

    I ordered the controller from eTrailer - great customer service. I saw they had a wiring harness that clips into the factory harness. I ordered one of those also, for true plug-and-play.

    Parts:

    bc1.jpg
    I wanted to mount it where I could easily get to it while driving (for adjustments or emergency stops.) Since my truck has an automatic transmission, there is a "storage tray" where the manual trans emergency brake handle goes. Looked like the perfect spot for the controller.

    bc2.jpg
    With the tray removed:

    bc3.jpg
    Since the mounting surface is not horizontal, I made a template for a new mounting bracket:

    bc4.jpg
    And built a new bracket out of aluminum:

    bc5.jpg
    Controller mounted:

    bc6.jpg
    Tray trimmed to fit:

    bc7.jpg
    It works fine like this, but I think I will clean up the trimming a little bit. Not that anyone would see it other than me...
     
    Last edited: Jan 9, 2016
    Scott B., Jun 22, 2015
    #40
    308savage, mallege, medic2230 and 1 other person like this.
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