96 Tacoma Overlanding DIY budget build
- Thread starter Tacoverlander
- Start date
Tacoverlander
Observer
Thanks!
Tacoverlander
Observer
Thanks! Im glad I made time to build this one as well...It has been really handy to have the extra clearance in the back. Not to mention I like the way it turned out. :sombrero: Plus I learned a ton. You can never go wrong an opportunity to learn something, especially when there are no major sacrifices to your rig...lol.
Tacoverlander
Observer
Thanks for the compliment!
Tacoverlander
Observer
4Crawler 1" Body lift follow up.
In preparing for a trip through the GA mountains, I got around to re-torquing the 4Cralwer 1" body lift. While doing this I noticed that I never installed the 1" bed spacers between the cross rail and the frame due to the bed already sagging a bit before the lift was installed. I decided not to install the spacers because I knew I would eventually get around to correct the sagging bed. I figured now was as good a time as in. soooo.....
This is what the bed looked like before...
I gathered some scrap metal laying around the shop and cut it to size... (2" square tubing, 1/8" thick, cut in half leaving me a 2"x1" C-Channel)
I then welded some end tabs this to allow me to bolt it to the frame. Looks like this
This was a quick project that should've been done a while ago.
BEFORE: AFTER:
Don't mind the bolts being off-set a little...There is a gusset behind the frame that forced me to do this... The OCD in me absolutely hates this...lol
In preparing for a trip through the GA mountains, I got around to re-torquing the 4Cralwer 1" body lift. While doing this I noticed that I never installed the 1" bed spacers between the cross rail and the frame due to the bed already sagging a bit before the lift was installed. I decided not to install the spacers because I knew I would eventually get around to correct the sagging bed. I figured now was as good a time as in. soooo.....
This is what the bed looked like before...
I gathered some scrap metal laying around the shop and cut it to size... (2" square tubing, 1/8" thick, cut in half leaving me a 2"x1" C-Channel)
I then welded some end tabs this to allow me to bolt it to the frame. Looks like this
This was a quick project that should've been done a while ago.
BEFORE: AFTER:
Don't mind the bolts being off-set a little...There is a gusset behind the frame that forced me to do this... The OCD in me absolutely hates this...lol
Tacoverlander
Observer
huntsonora
Explorer
Nice truck!
Summitbeerowl
Adventurer
Howdy. Very nice job on the truck. Question on your body lift...Any issues with how everything went back together? I'm considering the same one as you for my 93 but am unsure about all the linkage. Plus do you notice your shifter being shorter now?
Tacoverlander
Observer
Thanks Summitbeerowl!
The lift went on perfectly with absolutely no issues at all. Even the steering extension spacer. Hardest part was just getting the wrenches in the tight places when installing the steering extension. I purchased the gas fill extension but never used it as it was not need. With the 1" body lift I did not have to install anything to the shifter linkages. However, I did notice the shifter being a little shorter but got used to it very quickly. In fact, it feels pretty normal now. Hope this helps! Let me know if you have anymore questions or if you want me to take anymore pictures to help out.
Tacoverlander
Observer
Thanks!
Tacoverlander
Observer
DIY Roof Rack Attempt
A few months have passed and I am just now getting around to update this thread.
Next up a roof rack... To start off let me say that all of this mess was just so that I could put a light bar on my truck. I really love the light that the LED light bars gives off BUT I've never really been too fond of how they look on 1st gens. So...
This is what I came up with...
This is how I did it.
Bought some 1/4" aluminum plate from a friend. He also had some strut that I was thinking I may use for the crossbars but I ended up tossing that idea to go with the 80/20 aluminum T Slot to save time.
Then I started working on the template using foam board.
After making the templates of the different pieces I transferred it to the aluminum and cut...and cut...and cut... Then I did some grinding....then a lot of sanding...
Now that we have the main idea taken care of, its time to figure out how to mount the lightbar.
This was my first attempt...
Using the original cheap mounts that came with the cheap light bar, I just welded some tabs on the end of some scrap channel that I had laying around. This cross bar was planning to be mounted to the side rails of the rack.
After looking at it from many different ways and possibilities..I didnt really think that this was what I wanted. I just felt like there would be too much stress on the mount when being jarred on the trail. So I scratched that. Decided to make my own mounts and just bolt them straight to the top.
Original Mounts.........................................My mounts
I just used Black oxide bolts to bolt everything together....which I later learned is the worst thing to use for something that will be out in the weather.... Black Oxide=controlled oxidation
A few months have passed and I am just now getting around to update this thread.
Next up a roof rack... To start off let me say that all of this mess was just so that I could put a light bar on my truck. I really love the light that the LED light bars gives off BUT I've never really been too fond of how they look on 1st gens. So...
This is what I came up with...
This is how I did it.
Bought some 1/4" aluminum plate from a friend. He also had some strut that I was thinking I may use for the crossbars but I ended up tossing that idea to go with the 80/20 aluminum T Slot to save time.
Then I started working on the template using foam board.
After making the templates of the different pieces I transferred it to the aluminum and cut...and cut...and cut... Then I did some grinding....then a lot of sanding...
Now that we have the main idea taken care of, its time to figure out how to mount the lightbar.
This was my first attempt...
Using the original cheap mounts that came with the cheap light bar, I just welded some tabs on the end of some scrap channel that I had laying around. This cross bar was planning to be mounted to the side rails of the rack.
After looking at it from many different ways and possibilities..I didnt really think that this was what I wanted. I just felt like there would be too much stress on the mount when being jarred on the trail. So I scratched that. Decided to make my own mounts and just bolt them straight to the top.
Original Mounts.........................................My mounts
I just used Black oxide bolts to bolt everything together....which I later learned is the worst thing to use for something that will be out in the weather.... Black Oxide=controlled oxidation
Tacoverlander
Observer
Roof Rack continued...
Then...I had this genius idea. "I should get some flush mount pods and put one on either side of the bar...
Ill tell you now that I scratch this idea too...but I'll entertain you for a second...
So far its still a good idea...
but then I drilled holes and bolted it to the top.
Luckily I decide that it was gonna be too bulky on the top of the truck before moving on to the other side. Just thought it wouldn't fit the overall look I was going for.
I was really sure how I was gonna accomplish this idea so in the meantime Ill get to putting the main stuff together. To attach the sides to the top piece I just took some 1 1/2" aluminum angle 1/8" thick and cut it to about 3". Then drilled the holes. After transfer these holes to the side and top plates, I proceeded to drill those holes...I think this is where I realized that drilling all these holes for this "bolt together" idea was gonna take a looong time.
For the cross bars I decided to jump my original plan of using the strut an went with the tried and true T slot. Once these came in I was able to drill the holes to attach these.
I then cut the T Slot bars to 42 3/4". Then tapped the end holes
Then...I had this genius idea. "I should get some flush mount pods and put one on either side of the bar...
Ill tell you now that I scratch this idea too...but I'll entertain you for a second...
So far its still a good idea...
but then I drilled holes and bolted it to the top.
Luckily I decide that it was gonna be too bulky on the top of the truck before moving on to the other side. Just thought it wouldn't fit the overall look I was going for.
I was really sure how I was gonna accomplish this idea so in the meantime Ill get to putting the main stuff together. To attach the sides to the top piece I just took some 1 1/2" aluminum angle 1/8" thick and cut it to about 3". Then drilled the holes. After transfer these holes to the side and top plates, I proceeded to drill those holes...I think this is where I realized that drilling all these holes for this "bolt together" idea was gonna take a looong time.
For the cross bars I decided to jump my original plan of using the strut an went with the tried and true T slot. Once these came in I was able to drill the holes to attach these.
I then cut the T Slot bars to 42 3/4". Then tapped the end holes
Tacoverlander
Observer
Roof Rack Continued still....
Put it all together to make sure everything fit
I ended up just buying regular mount pods and making my own mount for those as well to keep it close enough to the top piece to keep in line with the light bar. I will show a picture of all the mounts later.
For the feet to mount the rack to the truck, I just got some 3/16" rectangular tubing and cut the 4 corners out. Then I scored the outside corner of each allowing me to bend them fairly easy while making sure that the bend was in the scored area. This bend would match the contour of the roof of the truck. I then welded the score up and ground smooth. (Note the lines in the middle of two of the pieces are the factory weld seems when the tube was made...not where I welded. If you look closely you can see the heat penetration lines in the corners of each)
I sat the rack on the roof and placed some 1x4 wood underneath it to get it where I wanted it and then placed the feet where they would go. This allowed me to match the contour of the truck without too much headache. I traced the outside of each foot onto the side rails. Then drilled more holes...
I ended up drilling 3 holes in each foot to bolt them to the side rails. Then 3 more to bolt the whole rack to the roof.
This will give you a better view of the different mounts that were used...
From left to Right: 2x Mounts for the side and top rails, 4x feet for mounting the rack to the truck, 2x center light bar mounts, 2x pod light mounts.
Put it all together to make sure everything fit
I ended up just buying regular mount pods and making my own mount for those as well to keep it close enough to the top piece to keep in line with the light bar. I will show a picture of all the mounts later.
For the feet to mount the rack to the truck, I just got some 3/16" rectangular tubing and cut the 4 corners out. Then I scored the outside corner of each allowing me to bend them fairly easy while making sure that the bend was in the scored area. This bend would match the contour of the roof of the truck. I then welded the score up and ground smooth. (Note the lines in the middle of two of the pieces are the factory weld seems when the tube was made...not where I welded. If you look closely you can see the heat penetration lines in the corners of each)
I sat the rack on the roof and placed some 1x4 wood underneath it to get it where I wanted it and then placed the feet where they would go. This allowed me to match the contour of the truck without too much headache. I traced the outside of each foot onto the side rails. Then drilled more holes...
I ended up drilling 3 holes in each foot to bolt them to the side rails. Then 3 more to bolt the whole rack to the roof.
This will give you a better view of the different mounts that were used...
From left to Right: 2x Mounts for the side and top rails, 4x feet for mounting the rack to the truck, 2x center light bar mounts, 2x pod light mounts.
Tacoverlander
Observer
Paint and Install
Painted...
Lights installed
Mounted to the truck
All-in-all I think it turned out pretty good...Its still growing on me a bit. I definitely love having the extra light.
As far as things I would change...there is really only one thing I would change and that is the feet... Having the 3 bolts bolting the rack to the roof created a slight bend in the roof when tightened... In my opinion this is caused by having a flat surface 5" wide bolted in 3 different places to a round surface...at the time I thought the feet fit pretty good and did not see this issue until after completely bolting and caulking all the bolts and holes...If I were to do it again I would probably leave the 3 bolts holding the feet to the side rails but shortening how wide the feet are at the roof. Then only using 1 bolt through each foot into the rough....hope this makes sense...
Painted...
Lights installed
Mounted to the truck
All-in-all I think it turned out pretty good...Its still growing on me a bit. I definitely love having the extra light.
As far as things I would change...there is really only one thing I would change and that is the feet... Having the 3 bolts bolting the rack to the roof created a slight bend in the roof when tightened... In my opinion this is caused by having a flat surface 5" wide bolted in 3 different places to a round surface...at the time I thought the feet fit pretty good and did not see this issue until after completely bolting and caulking all the bolts and holes...If I were to do it again I would probably leave the 3 bolts holding the feet to the side rails but shortening how wide the feet are at the roof. Then only using 1 bolt through each foot into the rough....hope this makes sense...