OK, details it is.
The Weber conversion we bought from LC Engineering came with a small rectangular K&N air cleaner. We did not want to use that so we also purchased the adapter to go from the DGV to the stock air cleaner. The whole adapter and carburetor assembly is very tall, so I knew right away that the stock air cleaner would hit the hood. An hour of cutting and TIG welding and the stock air cleaner was made to fit, simply by cutting out the middle and welding in a new plate. Will post pics of that later.
At some point, the fuel sender stopped working, and it made noise like it was hitting the inside of the tank, so a new OEM sender was purchased (not cheap) and the unit was replaced. But getting the old, rusted in place screws out...that took patience. Strip or break one of those and you're done. I swear it took 40 minutes to remove the screws from the sender and the pickup. I wanted to replace the gasket under the pickup while I was in there.
After building the front axle, with new gears (4.56) and new everything else, I discovered that the tie rod sat about 3 inches from the bottom of the oil pan. A new set of flat steering arms is now on order from Front Range Off Road.
Moving to the rear axle, the housing had to be modified to fit the takeout Tacoma E-locker. I have not figured out how to do this yet without warping the mounting flange on the housing. After welding in the new area, flattening and smoothing the whole surface took quite some time to get right. When any welding is done in this area, the studs closest to the weld tip in making them not vertical anymore so some straightening was done there too. It's all flat, but I am working on an idea to alleviate this problem in the future.
The rear diff gears were a major hold up. The gears in the box were 4.88's instead of the 4.56's labeled on the box. Boy am I glad I always check the before install. After two attempts to right the situation, a new set was just not available, but they did hae a set of 29 spline 4.56's. So I got those installed, but now I had the huge flange to deal with, so to the drill press... Four new 10mm bolt holes drilled makes for a new multi pattern flange. I have to do this quite a lot actually so I have it down.
Here is a pic of the proposed bed. As you can see, I did not spend a lot of time on the drawing. I have been looking for a design program to help with this process and there really isn't one available. Yes, you can design anything in CAD, but then interfacing the drawing with a photo of the customer's truck so they can get a visual representation is just not possible...yet. I did, however, find some software that will help in the process and it will be ordered soon. I still won't be able to attach the drawing to the photo without some photoshop work though. Anyway, here's the pic.