40 Guy builds a 100 Series

[Rezarf <><]

The finished result is clean and simple, again these are to get me through the season until I can fab a roof rack or Prinsu comes online for the 100 series, or I cave and pick up one of the awesome Gamviti racks.

One done, one to go.

Knocked them both out. I have decided I am going to power them two different ways. I am going to run a diode off my reverse lights and allow them to illuminate every time the reverse lights are, as well as, a switch in the cab to turn them on when I want them without having the reverse lights come on too.

Sorry the truck was filthy but I had the time so I went for it. I'll try to post a few off/on pics if I can figure out how to do it with my camera. My 3 year old mechanic approves!

 

[Rezarf <><]

Next up, finish the wiring on the winch and start my dual battery install. I have to order one more breaker, some cable, terminals and heat shrink and I am good to start. Did someone say solar?

 

[toyotech]

Clean install on the LED light bar. Let us know how bright they are. I'm in the market for some roof rack 360 light and like to use single row led


Sent from my iPad using Tapatalk

 

[Rezarf <><]

I messed around with them and was stoked at the light output for their size, lots of spill and decent throw. I'll try to get some pics before too long.

 

[wreckdiver1321]

The rear spoiler keeps dust off the back window. I've had an SUV that didn't have one and it collected dust like you wouldn't believe.

Nice updates! I really like the small detail work you put in on this truck.

 

[nmatcek]

Great build! I'm diggin that Kelty carport. Going to have to look into that!

Sent from my HTCONE using Tapatalk

 

[RiverCityDave]

Dude your "get me through the season" work, is nicer than most folks full on fab work. Nice truck, Im subscribed.

 

[Bretthn]

I like the look of the rear lights in that spot. Lets see a night shot.

 

[Rezarf <><]

Slee rear bumper with tire carrier on,
Battery in,
Readjusted the TB to level from the droop after installing the Slee bumper/Tire carrier,
Winch installed,
Realignment on the front end
Hi lift installed
Road shower installed
Thule box painted and installed
Trasharoo installed
Sheep skin seat covers installed (temporary borrowed from a friend to test drive them).
Rear brakes installed.
New igniter coil on #5 cylinder
Fridge hardwired

Whew, been a hectic few weeks but we are ready to camp and wheel!

Pics to come!

 

[Rezarf <><]

Spent a week with the family at 2 of our national parks here in Colorado... The Great Sand Dunes and Mesa Verde. We even got into a little dirt and my wife took the wheel with our three kids 5, 4, 3 cheering her on. I simply love the 100 for family trips its so comfortable and drives long distances with ease.

 

[Rezarf <><]

Before our National Parks Trip I decided to get after the rear bumper tire carrier and bolt it up. Christo and the gang make an outstanding product and I got this one since it was welded up "wrong" and was told it wouldn't bolt up without modification. Once I got down to it I measured about a kerbillion times and couldn't see anywhere where it wouldn't bolt up. So, I enlisted another Cruiser head and went for it. It bolted up without issue accept for a widening gap at the top edge of the wings in relation to the rear quarter trim. My wife calls it my "discount gap"

Installation was easy. Unbolt the hitch, the bumper cover, and the steel bumper substructure and you have a clean slate to bolt to. Before:

The rear bumper cross member and chassis were in fantastic condition. I pressure washed everything underneath and considered a fresh coat of paint but in the end it simply wasn't necessary. The PO had taken good care of this cruiser and it was garage kept. I was blown away how clean everything was.

This was our first trial mock up and the gap was HUGE, after adjusting a few things and maxing out the adjustment in the up position we closed this gap significantly. It still bugs me but I knew going into it I wouldn't be a perfect fit, so I can't complain too much!

Once we got it all dialed in and bolted up, the gap closed considerably. This tire carrier is really well built. It operates so smoothly and adds a ton of protection to the rear and rear quarters. I am finding I already miss the access to the rear cargo area, there is a lot of stuff to unlatch, release and swing out just to pop the rear hatch anymore. I can't imagine I would like a dual swing out for that reason alone.

I am planning a few mods for the tire carrier swing arm and bumper:

• I already added a 3/16" thick rubber pad under the hi-lift to
• I am going to add a gas strut to aid in opening the swing arm similar to BIOR.
• I am adding some LED license plate bolts to illuminate the rear plate.
• I am adding a backup camera to the center of the rear spare center cap.
• I will likely add recessed LED flood lights into the rear and side wings of the main bumper.
• I am adding a CB hard mounted antenna.
• I will add a 6# propane tank, either underneath in the spare area or on the swing out itself for cooking.
• I am searching for a rubber/traction pad for the main "step" of the bumper. I used it a lot for loading the roof top box and it is super slick when your shoes or the bumper is wet.
• I am coming up empty trying to find a dust cap for the spindle, I need a dust cap that fits the 2.45" ID opening.

 

[Kaibab]

Just got done with your thread, nice build you gave me several ideas. Enjoy your rig.

 

[Rezarf <><]

Learned a rule last week, don't use the FJ40 on 35's to access the trail that you will take the 100 on to.

Got out last week to prerun a trail for our clubs upcoming FJ40's Only Run here in Colorado. I decided to run Middle St. Vrain and Coney Flats in our Rocky Mountain high country. The trail was great, I had great company and we got to head out midweek so we only saw one other rig. My buddy just bought a really clean 100 series and I think this trail made him nervous to use it, however, I reassured him this was a little "tougher than I remembered." :bounce:

The rocks were relentless and I tested all the new armor I put on... it all passed with flying colors.

Having a fun day off!

Some of the trail that was tougher than I remembered. I actually made my buddy drive it so I could spot him through the gnarly stuff, I think it stressed him out to hear the sliders working

I managed to rip my Comet SBB-5 Antenna off the mount. It pulled off the base, but as luck would have it, it threaded right back on and is working again. Jackpot!

 

[Rezarf <><]

Next up... Dual Battery's.

I plan on fitting two Optima 27's into the factory spot, I think I can make it work. I picked up a Blue Sea system to manage it and just scored 2/0 wire from my local metal recycler the other day to complete the main components to install it. I just gotta find the time to make it happen.

 

[Rezarf <><]

I've been enjoying the 100 and just rolled 300k. The other day my fan clutch seized up. Motor just got LOUDER, like a small plane taking off, it was most noticeable when starting or downshifting in the mountains. I poked around on Amazon (where I seem to find all my OEM parts these days) and found a factory Aisin fan clutch which was indistinguishable from the factory unit.

Aisin FCT-021$80.87 at the time of writing this.

Amazon.com: Aisin FCT-021 Engine Cooling Fan Clutch: Automotive

This was a :banana: job at most.

My steps to swap this out were as follows...
Remove the plastic engine cover (4 10mm bolts)
Remove air intake hose at the air cleaner and the at the throttle body (10mm or phillips).
Remove the 4 air lines on the air intake from the manifold.
Set the air intake hose aside.
One quick layer of Duct tape over the throttle body so nothing can get inside.
Loosen the top two fan shroud bolts (12mm) enough to slip some card board between the fan and radiator so you can flatten any fins.
Use two 12mm wrenches to remove the fan clutch hub bolts. (I used one as a wedge at the 9 O'clock position when facing the front of the engine and it would bind on one of the pulleys so I could remove the nut without spinning.
I unclipped the PS radiator hose from the clip on the fan shroud and pushed it towards the engine.
I needed to use a pry bar to get my fan clutch hub off the studs YMMV.
Once free I rocked the top fan blade towards the rear of the truck and started wiggling it out.
Once the top three blades were out I rotated the fan counter clockwise freeing one fan blade at a time as I pulled it up and out.
I had to pull the skid plate to get the wrench and 4 nuts that fell during the removal process
Yes you read that right, my fan and clutch came out without a hassle at the same time in about 4 minutes of wiggling. Getting it back in was the same.

While I was in there I tossed in a new OEM air filter. Should breath nice and clean now. It was amazing how much this quieted the cruiser back down. Now I need to figure out which of the bearings is whining I have a hunch its the idler bearing on the serpentine belt tensioner.

New vs. Old: All markings, stamping and fit is identical.