Stock Mod/ Daily driver Buildup **Lots of Pics**

[91blaze]

I may have gone over board with pics but who reads anyway! Bear with me as I post my build up on here while trying not to get completely ripped apart.

This is what I sold to buy a Toyota. It was completely trashed and needed work all the time, I’m hoping a Toyota will be more reliable but then I’m not expecting much as I’m hard on vehicles.


I found this for sale add on PBB
http://www.pirate4x4.com/forum/showt...13#post4395413

’92 regular cab long bed sas’d with about 4” of lift
Drivetrain: 22re
R151 5 speed
Dual cases (MC07 23 spline)
Marlin’s 4.7 gears
FROF Twin stick kit
FROF Crossmember with skid plate

Front-end: Hi pinion with 4.88 (precision) and arb locker
’85 axle housing
Bobby’s new full 30 spline front shafts & Birfs
Allpro’s hysteer arms
Tie rod and draglink from FROF using fj80 rod ends
FROF axle widening Kit (uses ifs hubs)
FROF high strength hub studs
Springs are Rusty’s off-road 4” yj springs
Rancho rsx shock
Allpro steel brake lines
Fj-60 brake rotors with ifs calipers
High Angle Driveline long spline front shaft

Rear-end: V6 case with 4.88 (Yukon) and arb locker
Stock ’92 housing with stock axle shafts and brakes
Track bar
Chevy 63” springs with buggy leafs (3/4 elliptical-can be bolted down for street driving)
CV (’84-’85 style) rear shaft

Bumpers: Front arb bumper with Ramsey REP8000# winch
Rear homemade bumper using 2” square tube, has receiver
Rock sliders made from the same 2” tubing, bolted to frame

Tires: 36” superswamper TSL’s (including spare) almost new condition
old school blackout aluminum rims

Other Mods: Transmission tunnel is tub’d to raise transfercase
No-name racing bucket seats
Fenders trimmed to fit tires
Hydraulic assist steering using ifs Toyota box and aftermarket cooler (one of the best mods yet!)
Custom bodywork

Pics of how I got it

[91blaze]

I traded the 36’s for 35’s so I can fit in the mod stock class at RROCK

First things first bobbed the bed and made the doors removable




new bumpers

[91blaze]

new sliders

[91blaze]

Then I needed to mount my winch, but with my Toyota at 114” wb and up against mostly Jeeps on jeep friendly courses I needed to find a way to keep it as short as possible.

So I did this

Hole in floor

frame plated and hitch mounted


from above, sealed with rubber gasket


I had to clearance the tunnel since I’m using a 9500 ramsey winch. Maybe someday I’ll get one of those tiny comp winches from someone.


A tube runs along the frame rail and into the cab with a UHMW fairlead.


tube comes out the front


I mounted it low so it fits nicely under the passengers knees


you can make out another UHMW fairlead on the new front bumper where it comes out.

[91blaze]

Then I needed to be able to do front digs so I waited on FROF to get the trailtough disconnect to fit on his crossmember. I decided to switch the side the handle comes out on.



I had to grind a little to get a bolt in


installed


Then you gotta have rear disc. I was gonna use AFCO weld on brackets but found the would need to be welded to the flange so I ordered up some sky brackets. Lets just say I was a little less than pleased with them


I had to grind the little nub off too


And the holes stripped my caliper bolts
And I had to grind the calipers to fit a 15” wheel and the pads only engage ¾ of the rotor.

[91blaze]

Next was the proportioning valve, line locks, cutting brake and plumbing.
Tip here – Don’t waste your time with a rent-a-tool flaring tool. Go get something quality.

Cutting brake installed with proportioning valve right by me for adjustments


FL line lock


FR line lock


handles needed to be locked together for RROCK rules but I’ll unlock them for messing around on the trail

[91blaze]

then my wife installed the 5pt harnesses from ??? PBB vendor – good stuff


With all these new gadgets in the truck there’s a lot of stuff going on so I contacted 12voltguy.com to clean it up a bit and get me a custom made switch panel. It covers the stock parking brake area. I apologize for the hasty install but I did it 2 days before the first comp and just needed it done.



Things that I don’t really have pictures:
Front and rear One spline d-shafts
Rocklights mounted in sliders
I removed the buggy springs when I shortened the frame and made shackles for the 63” chevys.
The transmission had the wrong seal on the output shafts and after running it on the highway for 45mins I burnt it up. All the oil had been pumped into the transfercases. So that was removed and rebuilt. I also installed the larger clutch and flywheel. And as soon as I got it I did the timing chain, which even though it ran good the guides were broke. I also replaced all the stuff on the front that gets removed during the timing chain replacement, water pump, oil pump etc.
I beefed up the steering stops with 3/8 cold rolled rod, and replaced the knuckle studs with FROF ARP knuckle studs.
Built diff guards from 3/8 strap bent around a spare housing I had

[91blaze]

Then it was time for an exo, which I hate exo’s but the cab is already too small.
This is the part that I couldn’t find on the PBB so I thought I’d elaborate here.

How do you get it close to the body and still weld all the way around?
I decided to design it to lift off and weld all the joints and then slide back on.

Start

[91blaze]

welding enough for removal





Then on to painting it and the truck. I’ve never painted before and I spent about 300 on all supplies and paint and it came out great, not perfect but good enough for a rockcrawler

My booth


primer


paint

[91blaze]

then we slid the cage back down and welded it up good and touched those areas up

[Pook]

interesting winch setup...

so that tube runs right through? I guess you'd have to brace it pretty good at the end for side pulls.

[91blaze]

Close to done so we took it to the Big Meats run in Disney OK to scratch it up

Door bar made with cup holder


Dent #1


Dent #3??


rear bumber got the full weight of the truck on it and it bent


On the way home this cow got hit

[91blaze]

After the first couple times out with the truck I decided that the MTR’s just weren’t gonna cut it in the terrain at rockport so I got me some Krawlers!!. They absolutely kick ass!!


Oh and Winchline.com donated some spotter ropes for us to use during the competitions. Thanks Jim! I spotted Marc White last year in the super mod class and just used an ordinary rope and about killed myself every time I had to pull on it. These make it soooo much safer and easier on your hands.

[91blaze]

Then it was time to touch up a few things and go to RROCK #1 April 1st

The competitors


first course




OOPS


guess cage is too close


We winched thru the finish gate on its side. The final standings had us 4th out of 7 with 63 pts for 6 courses. The first to courses were 23 and 25 for us, I guess it was the jitters. The winner had –2 for all 6 courses but was also a sami. The courses were fairly tight and definitely didn’t favor my long wheel base. The krawlers worked great and everything else did too. It was a fun weekend.

[91blaze]

[91blaze]

The fairlead on the front bumper takes all the side loading and it is attached to the bumper only. The tube is braced/welded to the frame as much as I could and the ford shock tower is mounted to it and braced even more but the picture of that is too dark.

[shawn0890]

nice build up. i like the exo. if i had a tube bender i would make mind like yours but make the center winshield pieces removeable. but thats just me. also is it really possible to fit two people comfortably in that thing with the winch? i mean it does look like you mounted it as low as possible but still toyota cabs are small to begin with.

[willymutt]

The winch sits nicely under you knees when in the cab. The only person that complained about it was Leah and she is only 5' tall, so her legs are way shorter than everyone elses. It almost feels like a thigh support when you are sitting in it.

[tanman2003]

cool thread and buildup.

[Box Rocket]

Very cool! Interesting approach with the winch location. Are you using synthetic winch rope? Wire rope could be a little scary if you had a passenger. Hate to get snagged by a stray wire across your leg.

I like how the Exo turned out as well. I've got an in-cab cage from EOR that I'm planning on putting into my reg cab. But I've debated doing an exo but I'm not a fan of the looks typically. I built my exterior bed cage so that I could tie in an exo later if I decide to go that way. Funny I copied KCJones design and yours is also similar. Looks good.

[paulwhat]

Nice.

[91blaze]

and here I thought I'd done something original? Oh well I like it

[cheap sunglasses]

I'm usually not too interested in competition stuff but that class looks really cool, maybe someday down the road I'll look into it.

That winch is certainly outside the box, I'd say it's an original rig.

[PARTYHOUND]

Yeah, I really like the idea of tacking the cage together on the truck, pulling it off, welding and painting it, putting it back on and welding it on.

[Greg_Canada]

Nice buildup! Truck looks good.