2004 Tacoma SAS

8sixFabrication

Active member
This long 5 day weekend, came with some decent progress, as well as some struggles. So updates will come across a couple posts.

Wednesday after work, I popped by my local DEQ to get the emissions testing done, and it passed as expected. The following morning, I got up early and went to DMV to get my VIN inspection, registration, and new plates. That was all a success, and now the truck is fully registered and back on the road proper again!

I believe it was Wednesday night, I extended the rear axle breather using an 80 series Land Cruiser fitting, some hose, and a little breather. I ran it up and executed it in the frame where the e-locker breather goes. The very end past the flare for the hose, on the fitting had to be trimmed off so I could thread it in without hitting the brackets for the wiring. Otherwise it was a simple upgrade and looks super OEM

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Thursday afternoon, I spent a little time cleaning up my mess in the garage. Then I couldn't help myself, and decided to throw together the sub and amp setup. The wiring is already there from when it was previously on the road. I had this absolute unit of a speaker sitting around, but in a box with improper air space. So I ordered this affordable ported box, and a mono-block amp. I did a super basic install to get me some bass, and good Christ it's absolutely crazy haha. I do plan on installing some component speakers, an amp with a DSP, and sound treatment to go along with the rest. But for now, the ghetto setup will be nicer than a deck and stock speakers.

That evening I went to a buddies shop and had the AC re-charged with a little UV die to boot, so I can check later and see if there are any leaks. I think when I had it re-charged the summer before it was wrecked, the dude didn't put the right amount of refrigerant in it, because it's never been this cold.

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With a shakedown run planned for Sunday, I set out to get the bump stops setup. I will spare the details of every little thing I did, because there was so much back and forth, it was unreal lol.

I landed on these delrin pucks(version 2) after a couple flex tests on a buddies fork lift. They were pretty simple to machine on my lathe.

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For the rear I came up with this setup for a bump stop. It uses a cheap amazon GM replacement bump, and a custom made mount that ties into the u-bolts. The washers were to add height. I will go back and make my final adjustments and paint them this week.

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Within that, I noticed the tie rod was contacting the radius arm really hard with full flex, and caused the steering to bind and not move. So I had to go back and forth between my friends train yard, and home to grind some clearance into the radius arm several times before getting it where things worked together. It still rubs a teeny bit, but its pretty close now.

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With that un-expected tie-rod clearancing done, I had to move onto the front locker wiring. First thing I realized, is that I ordered the wrong switch. Instead of a momentary, I got a regular toggle. It works, but I will swap it out for the correct one. I first did a test to make sure I had my wiring schematic correct. Then I wired the harness and ran it into the cab. I did forget to get a picture of the switch location unfortunately. However, it all works well. I need to go back, swap the switch, wire in a wire for when the dash lights are on, and improve how I am getting the power. But this gets me by for a trip.

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8sixFabrication

Active member
Sunday was the shakedown run at a local small area (LaDee Flats). The day was a pretty damn good success. I only rubbed 1 time, and will address that this week. The truck handled really well in the rocks. I definitely put it through its paces, and came away with a small wound, as well as lots of now rock rash on the sliders, radius arms, axles, and 3 of 4 wheels.

It was a short day on the trails, and we decided to run a long, super harsh forest service road for some views, and to test out the truck on washboards and big potholes.

All in all, it was a great day and I am impressed with how the truck handles. Most of these pictures are from my buddy. Thankfully one of us was taking pictures haha

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8sixFabrication

Active member
Today was pretty mellow. I cleaned up the garage (again) and got to work.

I first dug up the rack I made for the roof top tent and awning from a while back to make sure it still will work. It clearly needs a bath haha.

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One thing I have been wanting to address for a little bit was the remaining leaks from the forward T-case and Trans.

I whipped up this ghetto splash guard, and used Toyota FIPG to seal it all up. From what I can tell, the spinning from the gears flings gear oil up to the opening for the breather which is pointed out by the arrow, as well as leaking through the plastic bushing that the lever pivots on. I made this out of .020" stainless steel, and folded up the part from the center, to fully block the breather opening.

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I wasn't sure where the trans leak was coming from, so I pulled the shifter and saw right away what I did wrong. I should have put the splash guard on top of the spacer for the short throw kit. Then I put it all back together with Toyota FIPG to ensure it stays sealed. After that, I cleaned up all the residual gear oil enough to verify if I got the leaks resolved. If so, I will do a more thorough cleaning later on.

I will put some miles on it and check again later in the week.

That's all for now. Hopefully some more updates this weekend.

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8sixFabrication

Active member
Small update this week.

Not much progress, due to some long overdue yardwork time.

I crawled under the truck the other day to check and see if the transfer case, and trans leaks were resolved, and those 2 that I fixed, seem to be dry. HOWEVER... now the rear case is leaking again from the output flange and the shifter... kind of frustrating, but I'm trying to not let it get to me. I just hate leaky trucks.

This evening I wanted to accomplish something. First thing I did was pull out all the standard hex head hardware holding the fender flares on, and replaced it with these button head like screws from a tailgate. The idea is that if the tire stuffs hard enough, it won't be catching a sharp edge. I did rub one time on the trip last weekend, but after looking closer, I think it was on the lower side of the fender. So I bent that back into shape.

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A buddy had a good idea for my gas filler neck trim. Since 3 of the 4 fasteners were broken off, I drilled them out and re-tapped for 6mm, and got the trim put back together. So that's nice to not have the door held shut with duck tape haha.

That's all this week. I have been driving it everywhere. It's got about 1100 miles on it now, which is great. I usually like to put at least 1000 miles on my trucks after major work, before taking it on a long trip.

I think next weekend should bring some more progress.

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8sixFabrication

Active member
Update time.

Life is throwing more curve balls, but I'm still pushing forward. With our trip to Moab quickly approaching, I've been slowly wrapping up little things.

The week before last, I got my rack modified for our current tent, and awning. I wanted to see how it rode with the weight, and how things would nest in the bed for such a long trip. I since have removed the awning because it makes getting into the tool box a pain in the ass.

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This weekend I wrapped up the rear bump stops. I cut off the square tube, and formed some 3/16 flat bar to be welded on and painted.

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Next I made a skid plate to protect the bottom of the radiator/power steering hoses. I don't have the ability to form this width of material, so I just made it out of a few pieced of 1/4" flat bar. It shouldn't see the abuse a skid plate or rock slider will, so it doesn't need to be as bulletproof.

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Lastly, I got my new fairlead installed, and license plate put on better. I need to re-tie the rope, but currently don't have much time to mess with it. So this will work fine for now.

Fortunately I'm pretty close to the end of my prep for our trip, so there won't be many updates that often, for a while.

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grizzlypath

Active member
Radiator guard looks nice. The 1st gen radiators drop so low! I've wondered if there's a comparable radiator out there that's slightly thicker, but shorter or something that I could swap in so that the radiator is tucked more up.
 

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