1998 T100 Expedition Build

Anota

Observer
I grabbed my new (to me) '98 4wd green extended cab from a friend. Second vehicle I've owned. First project was a 1973 Vw hightop camper that i was going to drop a v6 in but couldn't refuse an offer I got on it so let it move on down the road..
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This truck was a Massachusetts vehicle until my friend picked it up at around 200,000 and drove it to hell in Vermont until 260,000 when i picked it up.. Im a student on a very low budget so I'm going to replace things as they break. I bought the truck for $2400 which i think is close to full retail considering the mileage but all-in-all, before i purchased it, my friend dropped $$ on all new brakes and tires which ended up around $1500 so i couldn't complain.


The suspension is absolutely shot so this is my next project. Front right shock actually is snapped in half and the truck rides very rough. Engine and trans are in great shape as far as i can tell and 4x4 engages fine. might replace trans fluid just because. Picked this info up off of another thread and will be going with these new shocks all the way around: KG5474 front, KG54105 rear.

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Dash cluster is getting older because every needle kind of jumps around. Oil is full but on the dash it'll jump between empty and full consistently. Speedo also vibrates above 50mph but generally sticks around the actual speed so ill look into all that soon. New 02 sensors and exhaust so all good there. I plan on towing every once in awhile so ill need to splice in a trailer light harness. also interior lights are dead so thats another project. Also might look into killing the buzzer.

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The end goal of this truck is to build an expedition vehicle that i can live in. I have 5+ years of self-taught fabrication skills so can really weld up anything i need anytime which will be helpful with building a camper insert and bumpers. Building a front bumper now. Also don't mind the crusty black rims that will be all gone soon. Personally, I do not like black on green i don't think they compliment each other well. As a vehicle that will be lived in I want it to be as presentable as possible to avoid problems because aesthetics can really be the difference. So I'm going with green on gunmetal (darker semi-metalic grey) for rims and bumpers. This coming weekend i plan on taking the bed off and taking care of rust and figuring out what else I may need to do in the near future

This is really just a journal to share and log my work in one place and also my budget- cheers! Also have this up on Toyota Nation for the more direct mechanical problems of T100- This is more for the build-out of the truck as a whole
 
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dman93

Adventurer
Welcome, I saw and commented on your post on TN. Looking forward to seeing another T100 buildout. Mine is stock except for Bilsteins (guess that's not really a mod, at 188K that's juts maintenance :) and I've some added remote control for my FlipPac interior lights and power outlets. I'm still running stock 16" silver steelies but will paint them soon, so I'll be curious to see ow the gunmetal gray works out.
 

Anota

Observer
Yeah I'm just going to run everything stock unless i have a real reason to change it! In the mean time ill tidy everything up, stop the rust, and repair anything that needs it. Because I'm at school during the week i will be updating, hopefully, every Sunday or so on my weekend work. Saw a pair of 'helper springs' on TN but the seller won't respond- wonder if it would help handle the weight of the future camper shell
 

dman93

Adventurer
Saw a pair of 'helper springs' on TN but the seller won't respond- wonder if it would help handle the weight of the future camper shell
With stock springs and 188K miles, my 400# FlipPac plus a bit of camping gear, bikes and a passenger seem to make the ride just right ... better than empty but not too much sag. So if you're just adding a shell, not a slide-in camper, I'd not add helpers.
 

huntsonora

Explorer
Dash cluster is getting older because every needle kind of jumps around. Oil is full but on the dash it'll jump between empty and full consistently.

Your oil gauge has to do with oil pressure and not with how full the crank case it. Its perfectly normal for an oil gauge to move up and down or in your case side to side
 

Anota

Observer
Boring little update but this guy came with the truck but didn't fit. chopped the base to extend the plates that bolt to the frame 1" outward on each side. It torques the vertical plates a little but I will be reinforcing with gussets and whatnot. Also cut the light guards and extended them 2 inches each to properly wrap around the lights because they were scraping when as I mocked up and didn't want to deal with that. I might cut them off though don't really like the look. Next up will be turning this into a front bumper also. where it will be an bull bar/bumper/skid plate. All with aluminum paneling to keep it light weight and rust-free! Might do an inset light bar inside the bumper- funny all the steal come from fencing around my parents lawn that we are ripping up heres some pictures of what I've got so far

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Anota

Observer
Progress is slow due to school but I've been playing around with ideas for the camper cap. This is a rough idea of what I'm thinking- would love any and all input! The top is open in the rendering because I plan on putting a full all-season pop top for head space. The reason I don't want to go too tall is purely fuel economy so I'm thinking up solutions for that. There will be double doors unless I decide to go with a full swing out door. I can cut all the glass I need by hand and/or use thick acrylic which might be better.
The front bunk is 48" x 67" x 12" which is enough for me to lay completely stretched out but might be a little short so still might have to go taller. The goal of this design is to have a permanent bed space with plenty of other room to move about. The frame will 2" steel tubing with tabs for plywood to bolt onto with some insulation and an outer layer of aluminum paneling. I want to keep this as lightweight as possible and if anyone has any advice please let me know
 

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dman93

Adventurer
I don't have the design or fabrication skills to do anything like this, so Im always amazed and impressed when people tackle these projects. It looks simple and functional. A few comments, however, based on years of experience taking other people's designs of fabricated products to mass production:
- Why round tubing? Square or rectangular (oriented as needed for stiffness and/or mounting surface) would make it easier to attach the skin.
- I realize steel tubing is cheaper and easier to fab (and round is easier to bend, maybe that answers the previous question), but mixing steel and aluminum is never good in the long run with galvanic corrosion as well as the need for fasteners vs welding, though adhesive bonding may be enough for a skin.
- Finally (and this is a question for which I do not have past experience), do you really need plywood at all? Foam plus aluminum can be plenty strong and stiff, and much lighter, as long as you add some vertical or horizontal crossmembers in suitable locations for attachment points for tie downs, shelves, awnings, lights etc before you hide the frame.

Good luck - a low profile cabover plus pop top seems like a winning combination. I really like the side windows - provide light with privacy and gives a cool stealthy look. I know there are many options for opening side windows (sliders, pop-outs, windoors) but I never open the sliders in my FlipPac (perhaps I would if I had a dog traveling back there) and its just another place to leak. Oh, regarding window material. I did make a new lift gate window for my FlipPac, out of acrylic, and it has gotten pretty scratched up on the inside when dirty stuff inside the shell has rubbed against it. Otherwise it was cheap and easy to make.
 

Anota

Observer
Dman good question on the round tubing.. Personally I would go with square stock so mounting everything would be easy and flush to the plywood but I'm building as cheap as possible (broke college student) and i have tons of tubing free to do with what I want. Not much has been done on the truck which is a bummer. Got the shocks in but turned out to be four 2wd KYB gas rear shocks(?!) so they all have to go back. did some fun flex tests on the rear today. Truck has been running great valve covers are leaking a bit so Ill have to get new gaskets installed- going to start on the cab build this week
 

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ToyotaRoamer86

Adventurer
I'm running to 265/75R16 and I have no rubbing going on but in major front flex. Also just added new Bilstein 4600 from 4wheelparts, fit great and perform awesome.
 

Anota

Observer
Finally got the right shocks from KYB. New gas adjust all the way around and the truck rides like a dream! takes bumps like a normal car should not a rough ride anymore. One major problem still is while i was putting on the rear right shock i found out that the U bolts and bracket that clamp the leafs to the rear axle froze about an 1/8th inch tall so there is 100% slack enough to let the top leaf spin about 5 degrees. not happy about this so ordering new U bolts and going to restore that brackets. also front left upper shock mount is toast to so i need to weld in some new steel. Hopefully next weekend I could pull the bed and start on frame repair. Also got the monstrosity of a brush guard on that came with the truck. Clearly not meant for a t100 as you can see but i can make it work. the light bars are about 2 inches too tall so I'm contemplating cutting them off completely or moving them down if i really love them (I'm indifferent right now) also logged over 400 miles in surfing trips in the past few weeks. waves have been amazing this winter in new england
 

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Anota

Observer
Stripped the ****ty black paint off the rims hopefully getting them primed and painted today. Just bought an add-a-leaf pack that should come in a week or so. Scored this aluminum cap for $75 with hardware and 2 keys which is so sick. So I'm scratching the full build of the cap and taking this cap and modifying it to my design.. also got some crazy good surf in with a few really good guys. haven't been able to test out the truck offroad at all yet so hopefully next weekend couple friends and I are taking our rigs for a camping trip
 

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