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The Expo Dawg Build

Discussion in '4Runners' started by Scalded_Dawg, May 16, 2014.

  1. May 16, 2014 at 8:07 PM
    #1
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
    #36397
    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    Here she is, current state (29 Mar 2015)
    a1241879cf79e26dd571d57e04c595ca_631909781cd9f20724bf1854d5e2fecadad0d89e.jpgf98e7d6be36ae120fc8727a3eab3918a_520abc36c62a51635bd91ca1b4a8f96f8f0f0ab1.jpg


    (29 May 2014)
    esutaju5_805e14076c1ccf15247c44a139cdc20c461960a4.jpg


    (16 May 2014):
    IMG_0537_d5388edfcf8035811a1b85ba946c1dc2b63191fe.jpg
    IMG_0536_cb43f3c7cd3a4cd78492bd919346951fde869cac.jpg


    SO... I've had this 2nd Gen '95 4Runner SR5 since Sept of last year and just haven't put together a build page. Now that I've done a few things worth reporting on a build page, I figured I'd put one together. Here is her story:

    I picked it up off of CraigsList locally for $1200, it had some engine issues (explained below) but ran, no rust underneath, body is really straight and interior only has a few minor wear problems. Had 158K miles on the truck at purchase. The main purpose of this truck is a project vehicle. It is an expedition build with good road manners, drivability and moderate off road capability. I want to be able to go out hit some trails and see stuff - off the highway - off the beaten path. Most mods will be focused towards that goal.

    Here she is the day I brought her home:
    IMG_0197_145266891079367b4aa64dafc22d9ede76615f4b.jpg
    IMG_0192_3f8957410782c66175858448b7233ba3d2c79e17.jpg

    She had a slight smoking habit:
    IMG_0199_12c56033b7be33ab318b9838d53a131df15d48f3.jpg

    #6 Spark plug looked like this:
    IMG_0202_1cf16364977d26ac2ae0080b483fa537b4e0aeea.jpg

    And it's matching cylinder:
    IMG_0230_90912178c8d757e6d36c12a876e70e90a30d854d.jpg

    I believe the PO had a blown head gasket that they drove on for a while then had it repaired but by that time it had damaged the cylinder; it was burning oil bad in the #6 cylinder. This was more than they wanted to repair so they just drove it some more and sold it. It would smoke really bad for about 10 minutes after start up but finally get hot enough to burn it all out. Honestly, it ran pretty rough... LOL!
    Since it had this problem and the rest of engine was an unknown condition to me, I went ahead and rebuilt the whole thing, heads included.

    Some minor drama involved here... the original block had been rebuilt by Toyota on a subcontract with Jasper engines (most were in the days of the head gasket recalls). Apparently, in the subcontract they just repaired the damaged portion of the engines, this block's #6 cylinder was MAX bored .060 over, all others were still stock sized... the original block was worthless. I found engine another in a salvage yard and bought the entire engine, intake to oil pan, for $300. I tore it down and took the second block to my machinist; it was rebuildable. hat engine was junked due to a spun rod bearing. He tried to re-use the second crank but it exploded in the turning lathe :eek: So we used the original crank. Also found one of my original heads and been reworked poorly, so I used one of the second engines heads to replace that as well. That junk yard engine was well worth it in the long run.
    IMG_0279_d394c5455f2aea9aeef5983e1a4b4e67eed259ca.jpg
    IMG_0280_277d4a3146a0b99b0743ac56b0056dc7a2b22dde.jpg

    IN this pic you can see the new injector wire pigtails. I installed the FlameThrower 4 Hole injectors for increased atomization of fuel. Are they better? Frankly the engine ran so bad before, any thing is an improvement! I'm certain they perform better but I don't have much previous reference to judge against.
    IMG_0283_aa4087e2d115cf82632af2cc18037144b66c91f3.jpg

    Ran into a few problems during the final stages of reassembly... this one head had two holes that the threads stripped right out of (YES, I was using a torque wrench):
    IMG_0288_da38e06c762913445d91695d51f180cec97aa472.jpg
    IMG_0290_979075a12958d0ffdfaea5365f22186475324aeb.jpg
    Prepped for surgery: I got some HeliCoil inserts to replace the stripped threads; drilled out the hole, tapped new threads and screwed in the inserts. Easy stuff!
    IMG_0291_10c635c80a12ceaf97b473f567a2ec8f7155babb.jpg

    Ready to drop; in this photo
    IMG_0292_4631c02867920adc82261de449d430aacff7d687.jpg
    IMG_0293_ca82e15044e54a985f98f282cf834b564c0765c1.jpg

    This engine rebuild brought to you by:
    IMG_0265_407c638cea29e3fcdc62324f64a03c6ebdee7b33.jpg

    Back on the road (Nov 2013):
    IMG_0294_2a403500d8628c3e7cd26ac5eeeae8af4690cc0b.jpg
     
    Last edited: Mar 29, 2015
  2. May 16, 2014 at 8:08 PM
    #2
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
    #36397
    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    After I got it back on the road, I drove the crap out of it for a couple months.
    This helped to make sure the rest of the drive train was good to go and wring out any more bugs.

    First big mod to complete was the lift. I used 1.5" ball joint spacers for the front (side to side leveled with the torsion bars) and the rear coils springs from a '93 FJ80 Land Cruiser. (gained +1.75" on each side in the front and +4.5" of lift in the rear).
    The ball joint spacers are really straight forward to install. The FJ80 springs aren't difficult but the are considerably longer coils so you nearly have to completely remove the rear end to get them installed. I also built a pan hard top bracket; completely jacked the design from 4Crawler. I didn't take any pics of the lift install but here's the results...
    Before:
    IMG_0393_e771d732f38faf56835a86ea40a0dbda4c49275c.jpg
    After:
    IMG_0395_511b66a4e7aade89efd07ee6ed9bb15acc42723e.jpg

    Next major mod was a custom front bumper build. I didn't like any of the available bumpers for the 2nd gen T4Rs, so I borrowed several aspects of bumpers I liked and built my own.

    First built it out in foam board:
    IMG_0301_30e34e89c4259a03ef24bb34ee4925016988cf53.jpg
    IMG_0302_b00433421436cc102853524263157cfdc312b828.jpg
    IMG_0304_d8fff660d168d25548c3358bd3cdc5bc00b1cd43.jpg
    IMG_0312_9c443f4e59a17dac8e553b2a0d80b5ad4911dfae.jpg
    [​IMG]

    Spent a disgusting amount of time cutting all these pieces out of 3/16 plate steel with my angle grinder with a cutting wheel:
    IMG_0322_2f66da0cbe19c81f23636d9bab6f247749e5aadf.jpg

    Time for some of this
    IMG_0331_c05e6d9fdabab2ccad80249075e1e3e7af3bb646.jpg

    I bought this frame beef up plate to save some fab time
    IMG_0339_3f0bb5583a876855b308458d10780349022f94a0.jpg
    IMG_0340_2251cc7f53fee2d931273a4752d34493c2179407.jpg
    IMG_0350_0273ff36348f78fdc3b10a7a1232803531033778.jpg
    IMG_0351_b2d54065b55e4fb36c8d11264c454c0fb4c04402.jpg

    All this mil scale on the plate steel is a bitch to remove... until I figured out the acid bath trick
    [​IMG]
    IMG_0348_d8e475accc38dae9b557744a6b2add634b82abd8.jpg

    Time to tack it all together; this center box winch plate is 1/4" for the winch mount and down to the frame mounts
    IMG_0355_89710221ab96d9187846a3bda8ff6a9ca26253e9.jpg
    IMG_0357_ead12ce8dc9f08329b105fb513b2ef46bf798064.jpg
    IMG_0360_a9c504349e8f9b6bc5176b8a964084f9b2f7183b.jpg
    IMG_0416_cf60bac3059302b36032621689bbc66b4ab53f35.jpg
    IMG_0415_5a6666259db1f20bb3a38ce0fafb8cc25c504eff.jpg
    IMG_0424_72d87a970f08c0ff0f2baaf9dc80ccc2ec98b1e0.jpg

    I had a professional weld up the center winch box due to it all being 1/4" steel and my little welder would barely do 3/16" with prep work
    After getting it back I was able to finish it up:
    IMG_0466_395efe430af7dfbf0f34a78039bb217c0b7460bc.jpg
    IMG_0467_1669e9f4830e0774358949887ad1331b76d72e44.jpg
    Primed up with etching primer:
    IMG_0469_b300618b5ac143f34c12434ca96736e266a6c40c.jpg
    Decided to paint it with this:
    IMG_0470_d7e7006f82b29ef9f2835e451b47174c6001d479.jpg
    IMG_0477_5929911087991b62bedf92a18a058cf6b6021ffb.jpg
    IMG_0478_c9da929acb2191df44bf2a50179b7668aff3ee49.jpg
    IMG_0481_7c0f0c38bed5e01c227bf9d165020ccd4a439919.jpg

    Installed:
    IMG_0483_6ba6bb71b07c2e6ac1be30917dbb2c2e907ce361.jpg
    IMG_0484_c2571ba60937e29297fdc622ec58bf73bc804add.jpgIMG_0486_771a6da9be02e91423d0ca4053e9f32d843b450a.jpg

    I chose to put these very small turn signals in the bumper corners to replace the stock location ones; they are actually really bright.
    I did have to also install an LED resistor to stop the hyper flashing:
    IMG_0472_8dc2f62c691f504625553c13945aa20690a3760d.jpg
    IMG_0479_69084a8b71b25614129c3735745bee0ce5973979.jpg
     
    Last edited: May 17, 2014
  3. May 16, 2014 at 8:08 PM
    #3
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
    #36397
    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    Next was a couple of maintenance mods:
    LED cabin lights:
    IMG_0311_aeef262a411a2c8a68511699206446596a5320e3.jpg
    IMG_0310_ca88cd558e8ec673bd44bf1f02261a0d2bbfa65c.jpg

    New brakes and front hub spindle bearings
    IMG_0397_2fb80746d41ec2c05e3b1347e34ab462fc47abeb.jpg

    Went with an upgrade of slotted and cross drilled rotors with ceramic brake pads
    IMG_0398_9b27f90c5dcf6dddd69d01681daf04fd01e28493.jpg

    Also found these manual hubs locally. Changed out the drive spindles on my ADD front to save some wear and tear on the front drive train.
    These just needed some clean up and fresh paint... good as new:
    IMG_0508_d1fb28cddc00ef841b76fa15ea420962d9f804a3.jpg
    IMG_0510_0328e1f9e0dabe6174457694f30d9fca1c81de2c.jpg

    Time for some of this:
    [​IMG]

    Got some new shoes:
    IMG_0519_cfc5a0270acabe924a5a5f62d62df9ca3a517d2c.jpg

    Using the Tacoma Sport rims on the new shoes; backspacing is VERY different.
    This is the stock rim/tire side view:
    IMG_0534_7652f62ae236d2501a05a4a0dc9b9578755110b2.jpg
    This is the new shoe/rim WITH a 1.5" wheels spacer; only sticks out about 1/2" further than stock:
    IMG_0535_1ace0f7d538b99302b1fa5d197a1fae61c3fd3db.jpg
    [​IMG]
     
    Last edited: May 16, 2014
  4. May 16, 2014 at 8:08 PM
    #4
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
    #36397
    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    A few other minor mods:
    Some red LEDs in the map lights:
    IMG_9881_0b07de3d6ae22900fdc2c3650ca68af9d1caf0d3.jpg

    Radio Auto Antenna Kill Switch:
    Just tapped into the antenna command wire and put in this simple kill switch. If I'm going thru tight trees or brush I can lower the antenna... keeping me from ripping it off.
    uby6ynem_fd7218bee195347816d14ce6ea448915fe470166.jpg
    aha6u3eh_6a1657e63d7b30619c8e065238557acd6a6460e2.jpg


    CB Radio and Antenna mount:
    So I went with the Cobra 75WX/ST radio and a Wilson 1000 antenna w/ magnet mount. I plan to build a roof rack later and will incorporate a hard mount into that, so the mag mount is just temporary.
    I drilled a hole in the front side of my third brake light housing and ran the antenna cable thru a grommet, then sealed that up with some black rtv:
    IMG_0376_1af07f7295e32fb9b0af2144e0b9017499ead824.jpg

    My radio is mounted under the seat with an external speaker under there as well. Future plans are to mount the speaker between the head rest posts.
     
    Last edited: May 17, 2014
  5. May 16, 2014 at 8:08 PM
    #5
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
    #36397
    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    Forgot to add in my "bedside" decals"...
    I had these custom made by SteelCityAirman7 here on TW.
    The aircraft silhouette atop the compass rose is represents my 21+ years in the Air Force as a Crew Chief on B-1B bombers.

    Pics inbound.....
     
    Last edited: May 19, 2014
  6. May 16, 2014 at 8:09 PM
    #6
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
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    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    reserved 5
     
  7. May 18, 2014 at 10:26 AM
    #7
    lemons

    lemons LOCO 4X4

    Joined:
    May 5, 2013
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    #103567
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    929
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    Ryan
    Virginia
    Vehicle:
    07 TRD DC Offroad 4X4
    Icon coil overs W/King 14 inch 700lb springs and super bump bump stops, Allpro Expo leaf springs, Allpro Ubolt kit W/timbren Bump stops, Dif Drop Kit, Magnaflow Cat-Back Exhaust, Badges painted Rust-Oleum bed liner, Color Matched TRD Sport Grill W/Grille Craft Insert, TRD seat covers, Weather Tech Floor Mats, Flyzeye's , fog light anytime mod, ABS Off mod, ATO skid plates, ATO rear H/C bumper, BAMF sliders w/kick out, CBI front bumper, Engo 10000lb winch, Rigid D2 foglights, Piaa 510 fog lights, cobra CB w/firestix antenna, AFE snorkel
    Looking Good Brent. Great Build Page Too.
     
  8. May 18, 2014 at 4:43 PM
    #8
    Slimwood Shady

    Slimwood Shady I love your mom!

    Joined:
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    Hampton, VA
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    '17 Tundra; '16 Odyssey; ;14 A4
    Looks like poop :D
     
  9. May 18, 2014 at 4:59 PM
    #9
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
    May 2, 2010
    Member:
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    Messages:
    1,647
    Gender:
    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    Thx Ryan!

    Best compliment EVER! Thx bro!!
     
  10. May 18, 2014 at 5:03 PM
    #10
    Slimwood Shady

    Slimwood Shady I love your mom!

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    First Name:
    Linwood
    Hampton, VA
    Vehicle:
    '17 Tundra; '16 Odyssey; ;14 A4
    :thumbsup:
     
  11. May 18, 2014 at 5:07 PM
    #11
    ckeene9

    ckeene9 Well-Known Member

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    See Build Thread
  12. May 18, 2014 at 6:01 PM
    #12
    rbraddock

    rbraddock Well-Known Member

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    Randy
    Hampton, VA
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    13 DCSB
    6" ProComp lift from the dealer, slow build in progress
    Oh hell it's on like Donkey Kong!
     
  13. May 19, 2014 at 8:07 AM
    #13
    StAndrew

    StAndrew Wait for it...

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    Chris
    Hampton Roads, Va
    Vehicle:
    SR5 4x4TRD
    Intake, exhaust, lift. Typical stuff.
    Weak sauce. SAS that jank.
     
  14. May 19, 2014 at 8:17 AM
    #14
    Scalded_Dawg

    Scalded_Dawg [OP] Not as new as my post count would appear

    Joined:
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    Male
    First Name:
    Brent
    Yorktown, VA
    Vehicle:
    Stripped Steel and Sex Appeal
    Tacoma daily and 4Runner to play
    No.
     
  15. May 19, 2014 at 8:27 AM
    #15
    StAndrew

    StAndrew Wait for it...

    Joined:
    Feb 8, 2010
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    7,548
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    Male
    First Name:
    Chris
    Hampton Roads, Va
    Vehicle:
    SR5 4x4TRD
    Intake, exhaust, lift. Typical stuff.
    :eek: :mad:

    Un-sub'ed

    :brianr::brianr::brianr:




















    :D
     
  16. May 19, 2014 at 9:11 AM
    #16
    Wishbone Runner

    Wishbone Runner Because 4R

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    James
    CO
    Vehicle:
    04 SR5 4Runner
    King/Dirt King
    Awesome build so far, and nice work on saving the engine. Digging the home fab bumper as well, I feel you on the cutting with the grinder, did both of my bumpers the same way.
     
  17. May 19, 2014 at 9:30 AM
    #17
    ponethousand

    ponethousand Well-Known Member

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    Virginia Beach
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    regeared, locked, armor, and stuff
    DAMN! Great work!
     
  18. May 19, 2014 at 12:52 PM
    #18
    scrappletaco

    scrappletaco Damn Deer and Idoit Drivers

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    Josh
    Williamsport PA
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    2011 reg cab 4x4, Debadged and dirty
    Debadged, Removed Charcoal filter
    Really digging it. Makes me hope to snag one of these one day....... or buy my future wife one. If she ain't into yotas I'm calling the wedding off
     
  19. May 20, 2014 at 4:32 AM
    #19
    AaronArf

    AaronArf Well-Known Member

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    BRO'D Edition
  20. May 20, 2014 at 4:46 AM
    #20
    ajohnson

    ajohnson Glamour Shot

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    Things and stuff and such

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