Lucas's Tacoma rebuild/overland project

Arivalsend

Adventurer
Hey everyone I have been a lurker on this site for about two months now and I am putting an end to that. I am writing from my home town on the Upper Peninsula of Michigan. I have been into travel/ cycling / and overland exploration for as long as I can remember and so this site has really become one of my favorites.

I have found it to be a great resource for my own project. But more than that I have really enjoyed the community of outdoors/overland enthusiasts. And I am chagrined that this is one of my first postings to that community. In any case here it is.

For the past three years I have been planning an overland trip down in Central and South America in order to see some more of a world I had read about and also prior I have backpacked into and had only stayed in briefly. The trip was to be a celebration of my post college freedom and of graduation. A brief interlude away from my daily rutine, and before being trapped into gradwork and more student loans/body parts sold....yada..yada. And so after graduation in May I went about making this happen. I left for Colorado to work and began scheming about a vehicle build that would give me the mobility and freedom in my travels into foreign lands.

I sold a perfectly good 1999 3RD Gen 4Runner this summer in order to find and purchase a Toyota Tacoma. My reasons for this build and not a build on the 4Runner were several. The first was the Runner was using auto and I have always enjoyed a 5spd for offroad travel/exploration. Another was that as I would be using the vehicle for basing out of over long periods, I wanted something without the rear seats and carpeting and all the fluffier aspects of a 4Runner. And dont get me wrong I have seen some really bomber 4Runner builds but my stock 99 was a far reach from those.

After much searching and deliberating on my budget (which incidentally is not much as I work as a guide in Colorado in the summer and as a student/sue chef/jiffy lube mech/bookstore attendent...LOL......the list goes on and on in the school year) I decided to purchase a 99 Salvage Toyota Tacoma V6 5spd. Now you are probobly wondering why I would ever do such a silly thing and now looking back I am wondering much the same. At the time I had looked high and low for a TRD package in a ex cab V6 Tacoma and had no luck. I was also working with limited funds and decided to take on the work myself. So the truck I found had "light front end damage" along with a slew of other issues. Here are some pics for you guys to get a kick out of. Yeah the color is one that not every guy could pull off:26_7_2: .











The truck had to be shipped up to me and I just ended up paying out the kazoo. So in the end, my original instinct to shop only those trucks that I can go over in coveralls and toothbrush in hand. The truck arrived on a flatbed and it would not start up to roll it off the truck. I popped the hood and the battery was missing. So after rolling it off with a come-along and a little creative labor it was sitting in my yard. Not running with an empty gas tank and a steering wheel that was on upside down. Upon further investigation the passenger side CV was bent in and the UCA LCA were both ruined, ball joints bent up, passenger side rotor and caliper damage, 4 sheered lug nuts. The two frame rails in the truck where severely bent and it drove down the road at a right angle. Suspension was completly shot two rear struts rusted through and fronts totally worn out, stock leafs were ok but which I have since replaced. The vehicles hydraulic steering rack was unbolted and looked to have been tampered with. 1 rim/tire missing and spare on instead. On the positive the truck was not stolen...... I paid with shipping $7000. The engine/tranny seem to be functioning and have checked out with further diagnosis. T-Case and front diffs low on oil but otherwise working. And so it began.

Now as I told you guys I had sold the 4Runner to fund this POS so I had to just sit there and really think about my choices in the whole thing (of course this led to the conclusion that all rational thought had somehow vacated the day I bid on a salvage ebay vehicle). This was the start of the project three months ago.

I am off to work so to be continued
 
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Willman

Active member
Welcome to the ExPo!

For some reason.....i can't see your pictures!

Hope all goes well for you!

This is a great place as you said for a lot of great input and infor.!

:26_7_2:
 

p1michaud

Expedition Leader
Rebuild lies ahead

Welcome to ExPo.
You have some work to get the Tacoma running, but take it one step at a time.
 
Welcome to a wonderful site with very friendly people who will give you the help you need when you need it. You will like it here.
 

Arivalsend

Adventurer
Willman said:
Welcome to the ExPo!

For some reason.....i can't see your pictures!

Hope all goes well for you!

This is a great place as you said for a lot of great input and infor.!

:26_7_2:


thanks Willman. So far the site has been a great resource and also given some inspiration for future modifications.
 

Arivalsend

Adventurer
Streaker your build has been one that I have kept an eye on. I am envious of the clean upgrades and well thought out progression of your build. I can only hope mine comes together so well.
 

Arivalsend

Adventurer
Overland Hadley said:
Welcome to Expedition Portal!
Thanks Hadley great to see another upper midwesterner on the forum. I spent a couple years up in Duluth and so I know the appeal to that area. I am waiting to see how you end up tackling your storage/sleep platform am in the works on one now as well. Your truck is looking great keep posting those beautiful pictures.
 

Arivalsend

Adventurer
the work thus far

Well from that fated evening when my truck arrived in somewhat less than new-used condition :confused: I have been setting aside a couple hours every night to its construction. The first stage was to assess the damage and missing parts of the truck. Well that is of course after I called the seller and told him I was going to drive it out after I put it together and give him a good kick for his inane and misleading write up.

It turned out that I would need major frame repair in the front 3/4 of the truck. New CV's as the drive side was also pinged from the bend and of course the parts already afformention. I also discovered once I had the engine up and running that the harmonic balancer had been impacted and so was bent and nonfunctioning. So I rolled the truck into my less than spacious workspace, which is thankfully unheated as it gets very warm in these parts in the winter months:costumed-smiley-007




And so I started with the frame as the integrity of this would determine the entire project. As I do not have the tools or the know how to repair a bend such as this I brought the truck to a friends shop and there is stayed for about three weeks. The passenger side front wheel was pushed in about 3 inches off of stock and the two frame rails had both been pushed over as a result. In order to fund this I ended up doing the odd tuneup there and also all the cleanup/shop maintenance. I felt like the guy having dinner out who after the meal has to go back into the kitchen and spend the next four hours washing. Suds up right! Well the frame was eventually repaird and pulled back into some semblance of straightness. I traded time and cash on this and it ended up costing me an additional $400 (the buddy price .....or maybe not). But they told me it was the most clean things had been for years. This, it turned out was not the last time they would have me doing work around the shop. After replacing the control arms and cv's, along with the pass side caliper and rotor I was ready for alingment attemp number 1. This did not go so well as my wheel was still an inch off of stock. I was again at the collision center's door for another frame adjustment. After which the truck passed alignment and I spend a good couple days stretching and wishing I could say the same for my back after hours of drudgery.

On to the overall componentry. I decided to begin with the engine and its various missing pieces. Ahh back to the garage! :Mechanic: Better pull on the insulated coveralls.




During the frame repair I had taken the time to order several much needed parts. First a Optima Yellow top to fill a vacant space. A harmonic balancer and new timing belt/engine belts. The balancer was slow going and of course no impact so it was breaker bar/creative language and blocked wheels. Eventually the bolt spun out and the puller went on. From there it was timing belt and no looking back. The a/c radiator was also shot and so I ordered that as well. Once installed the engine bay was beginning to look a bit better. For any of you guys that have worked on damaged vehicles you know the frustration of bent sheet metal. Nothing seemed to line up and every part i replaced had to be fitted back into the front of the truck. The radiator went back in but only once I got out the big hammer and reshaped the mounting points so that it would fit correctly and not against the main radiator.

From here I tackled the steering rack which of course had been removed and the reinstallation of it was a process. I did order a set of energy suspension poly bushings and figured on doing those while I was wrenching on the thing. The outer tie rods on both sides were also bad and needed to be replaced. After another afternoon I had it back on and had pulled the steering wheel off in order to recenter it's cable. Finally I could drive around with the steering wheel on right side up. :wings:

I decided that suspension was the next order of business coupled with tires and steel rims. As I would be traveling into areas where factory aluminums would be non replacable. I tracked down toyota 16" steelies. But instead of going with BFG's, and I have I have had great luck with them in the past, I decided on a set of Toyo AT's which I picked up from a friend who was sponsored by them and so got a much better deal. With 5 tires to buy I did not have the bank account to go with the BFG ATs. Size was important and after much deliberation I went with 265/75/R16. I loved the idea of running Scott's 255/85/r16 MT's but as this is also my daily driver I went with a bit smaller set up and am hoping that I won't regret it dearly later.

For suspension I just could not compromise and I tracked down some Donahoe CO's and a Deaver 9 pack. Thankfully I was able to locate a guy doing a SAS swap on his 2002 Tacoma and he gave me a great deal on the package. Another cool toyota owner, thanks again John! I went with the 5100 Bilsteins for the rear. I must take a second to thank ExpeditionsWest for the detailed product reviews and fantastic website. This was a major help in the build and it was through your website Scott that I ended up here, so thanks. :26_7_2:

Well as any of you who have installed springs on a older vehicle know they don't want to come off without a fight. The shackle bolts on mine were no different and the hammer/sledge method did nothing, adding the torch into the mix also a no go, and finally with the help of my tiny 4 inch angle grinder and a couple discs I had the bolt heads off on shackles. The ubolts took more time, a 1/2 breaker, penetrating oil and an hour of slow work. Eventually they too came away. I took the time to install a longer stainless break line while i was in there and the Deavers went in without a hitch. I love them! Articulation is simply amazing and they have really improved vehicle ride. The donahoes went on without a hitch and are also a well put together product. I dropped them off of there factory set of 2 1/2", down about a half inch to straighten out my cv's, they thanked me later.





Once the truck was somewhat together I took it out into the wilds. Some of the almost tractless wilderness that is often so hard to find these days. Thankfully you can still find pieces in the UP of Michigan. Had the snowshoes along and got some great shots. Sadly my memory card is being impertinent and these will have to wait. The truck ran and ran well. We visited some of my favorite summer haunts and it worked great on many unplowed sections of logging road. Albeit I still have some bazaar tire noise I have not pinpointed as of yet. Had them balanced twice and still no go. Only happens on dry pavement and is a vibration sound that is almost as if something is rubbing. Another discovery was that my elocker was DOA! After all that trouble to find a TRD.....well after calling up the stealership I found out that it would run me $750 for a new actuation mechanism. And so it was back into my little garage and off it came. I tore into it as at this point it was already non functioning. After a afternoon cleaning and relubing the inner workings and then permatexing in a new seal and refitting the copper connections I had it back on and running like a champ! So here it is finally living outside of my garage.





I also picked up a slightly battered fiberglass topper. It feels right at home on top of my pickup and they both go to abuse counceling together on Sundays. This brings me up to date on the progress so far. The to do list for the next couple months includes

Front Bumper- Maybe ARB...more likely a fabed one done locally (price is always a factor even when you dont want it to be)
Rear Bumper- same- with fuel can mounts/ hi lift/ and cb antenna mounts. The key to both will be approach angle and utility/protection
Rock Sliders- I am at a bit of a crossroads. The set I have are made for the 4Runner and are a bit short of where they should be. Do I install them or put them up for sale and track down the correct size? Not sure if you need wheel to wheel coverage? Thanks guys
Second battery- any tips or links to threads on bed installs of this would be great. I also would like to have it powering everything and leave the cab one running only the starter.
Roof Rack and Basket- I have used Yakima forever and their racks are fairly well built and lockable. I am traveling with some other gear-windsurf board and bike- so a rack is madatory. Still debating on the basket any opinions would be welcome.
Rear Platform and storage- some great posts on this already and I am still trying to track down the video of Baja Taco's friend who had a lift away bed set up on hinges in the rear of his truck. It really got me excited and I since cannot find it.
Lights- already have PIAA's that are decent but may upgrade in the future and add a couple more.
Snorkel- trying to track down a used ARB for less than the upfront hit on this. Its not a necessity but from everything I have read they are great for getting your intake above the dust and grime. And any added water protecting is a major plus. The engine prep would also be essential and any info on waterproofing electronics would be great. Coil packs seem resiliant but what else may be at risk?
Aux fuel tank- Jerry cans so far but if the funds come up this is a maybe.
Aux water tank. This is a must and I am already working on tracking one down.


Well that is it so far let me know if you have any ideas or you want to comment my small and messy garage.
 
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Arivalsend

Adventurer
p1michaud said:
Welcome to ExPo.
You have some work to get the Tacoma running, but take it one step at a time.

Michaud thanks for the words. So far that is what I have been keeping my eyes on. One fix at a time and nothing more distant than getting out of the garage for that day. :Mechanic:
 

Rexsname

Explorer
Ref: Sliders...........I have DeMello square tube sliders and I love the length of them. Having sliders that are the wrong size will only irratate you every time you need to use them. Sell the short ones on line and buy, fab, make the right size.

REX
 

Arivalsend

Adventurer
Rexsname said:
Ref: Sliders...........I have DeMello square tube sliders and I love the length of them. Having sliders that are the wrong size will only irratate you every time you need to use them. Sell the short ones on line and buy, fab, make the right size.

REX

Thanks Rexsname I am starting to see that these are just not going to cut it. They are about a foot too short and that leaves a space on each end. They are solid Stubbs sliders and so I was tempted. Anyways I will get them listed and start searching for another set.
 

keezer36

Adventurer
Arivalsend said:
Second battery- any tips or links to threads on bed installs of this would be great. I also would like to have it powering everything and leave the cab one running only the starter.
Have you been reading RoundOut's Aux Battery: http://expeditionportal.com/forum/showthread.php?t=8558&page=6?
He posted a wonderful catalog for all the niggly little parts needed: http://www.bwdbrand.com/web_app/catalog/BWWCB-06.pdf
I'll be starting mine soon and plan on using the Hellroaring 95300B, http://www.hellroaring.com/bic75300.php from an Odyssey 1500 with both top and side posts, http://www.odysseyfactory.com/product_list.htm

The Hellroaring 95300B has two posts available for the aux battery to run parallel + cables from the batt which will allow for instant starting vice waiting to charge a dead primary battery (so sayeth Hellroaring). Personally, I feel that given the right AWG, you'll crank the primary right off the bat (no pun intended) but the parallel set-up intrigued me.

This is definitely a mod that is 90% planning to have it work and work well.

This wire gauge table might come in handy also: http://www.rbeelectronics.com/wtable.htm
 

4RunAmok

Explorer
BajaTaco's friend is Steve. A friend of mine as well, we've been on a few trips together...

You can find detailed writeups about his truck here on Baja's website.
http://www.bajataco.com/vehicles/steve_tacoma.html

It certainly is a great truck. He even set up a CABIN PRESSURIZER for the rear compartment to keep out dust while wheeling, and makes the night's sleep a more enviornmentally comfortable! Although I don't know if that writeup is on the site.

He even has an electronic pump with a water spigot at the back!
 
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4RunAmok

Explorer
By the way, put me down as another for Demello Sliders.

These guys do great work. Jason and Jack are nice guys too!

They also welded mine on in their shop in Corona, CA.
 

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