dyogim's 00 tundra build

[dyogim]

My truck has been a work in progress since the day I got it back in 2000. Anyways, you can read the progress here from then until now here: http://dyogim.blogspot.com

In more recent updates, I'm currently working on doing away with all the push button/ADD/electronic 4WD set-up. Beginning of 09 I started having issues with my 4LO. 4HI worked but, for some reason everytime I pushed the button for 4LO, the indicator blinks. Prior to the 08/09 winter season, it worked with no issues. So, I figure bad actuator at the tcase.

Mid summer, I went wheelin' and without 4LO, 4HI was working the drivetrain too much to the put where my trans temp light came on. I figured due to the slow movement and high rpm's things got too hot. After that trip, I installed an e-fan directly to the tranny cooler.

Instead of trying to fix the actuator on the tcase, my plans are to swap out the auto tcase for a manual tcase. The tcase I'm getting is from a 2.7 taco/runner 00-03. Which is 21 spline. The tundra is 23. Supposedly, the tcase found on the V6's of the same model/year use the same casing as the 2.7. The only difference between the two, is the outshaft length and spline count. If the tcase found on the tundra also has the same casing, I'll be removing the output out of mine and swapping it into the manual tcase.

Once the tcase arrives, I'll start the teardown and comparison. I'll try and take as much pics as I can and keep this thread updated....

[Doc Mayhem]

That is a great looking truck. I don't know if it helps, but the Tundra's that had a manual transmission also had a manual transfer case. I never liked my electronic transfer case. I fail to see what is so hard about pulling a lever.

[dyogim]

That is a great looking truck. I don't know if it helps, but the Tundra's that had a manual transmission also had a manual transfer case. I never liked my electronic transfer case. I fail to see what is so hard about pulling a lever.

Yes I was thanks!

Manual trannys for the tundras were only found on the V6 models. Which, the tcases for thoses should be the same as the v6 tacos/runners of the same year. However, may have different input shaft lengths. The tcases for those are the same for 2.7's except, the out put shafts are different, 23 vs 21 and the 2.7's had a shorter input shaft.

I don't know if the tcase on the V8 tundra auto (VF2BM) is the same case as the V6's/2.7's. I'll know when I get the tcase delivered to me tomorrow...

[dyogim]

To keep it simple, I'm providing the updates here: http://dyogim.blogspot.com/2010/01/ever-since-my-sas-ive-been-fighting-my.html#links

[dyogim]

I blame this light upgrade on 01tundra because of his LED upgrades. THANKS! LOL!!!

I've gone through many aux. lights but, none of the high end stuff. I just couldn't afford them. So, this upgrade may be for those wanting a good set of aux lights without breaking the bank on HID's.

I've always liked my previous set-up of my Hella 500's. Had a pair of fogs to light up the road directly in front of me with a wide beam pattern. And a pair of driving lights to light up the road furter down. Fog lens broke and I upgraded the driving lights to Hella 700's. With the 700's I upgraded to the HID Raptor kit from DDMTuning.com. Light output improved but, I still needed my fog set-up and the 700's are not offered in a fog pattern. I was looking through the list of products from Hella and which fog's I could use the HID kit with using H3 bulbs. Came across a pair of Hella Micro DE's on craigslist for $50. Took out the 700's, bolted the micro DE's and installed the HID kit. Turned on the switch and the light output and pattern, is exactly what I was looking for. The micro DE's light up the sides a lot more and with the HID kit, are very bright. The micro DE's also have an integrated cutoff within the housing. This way, I can actually run these lights while I'm driving on the street. They shouldn't blind/annoy other drivers as the cutoff is level to the stock headlight cutoff. I might have my brother drive in front of me to see if the lights are blinding/annoying. If they are, point them lower or only turn them on in the backroads or on those lonely highways....

I was worried about thieves trying to steal my new set-up. So, I relocated the micro's from the pre-runner bumper and installed them into my front grill. Here are a few pics of them installed. I'll post up night pics when I get a chance this week.

http://lh4.ggpht.com/_oJh5dgNo-iY/S9W2D0j3jZI/AAAAAAAADd0/8mJhJ3c7gg0/s800/P4251425.JPG

http://lh4.ggpht.com/_oJh5dgNo-iY/S9W2CvT8ELI/AAAAAAAADdo/ac0MRNL7ACg/s800/P4251419.JPG

http://lh5.ggpht.com/_oJh5dgNo-iY/S9W2DOc3BPI/AAAAAAAADdw/jr1haktPFgU/s800/P4251423.JPG

[01tundra]

I blame this light upgrade on jjc because of his LED upgrades. THANKS! LOL!!!

I'm "01tundra" over here......so if I'm gonna get blamed for something, at least get my name right punk :p!

[dyogim]

I'm "01tundra" over here......so if I'm gonna get blamed for something, at least get my name right punk :p! LOL!!!!

I cut and pasted from TS. Forgot to update your username....

[rambrush]

Are we all abandoning ship and running over here?
The lights are looking good interesting to see what they look like at night.

[dyogim]

Are we all abandoning ship and running over here?
The lights are looking good interesting to see what they look like at night.

LOL!!! No plans to leave TS. This place has been great with the change in interest on how I want my rig set-up. Lot's of great info and members here.

Anyways, here's the night pics:

Stock headlights:
http://lh6.ggpht.com/_oJh5dgNo-iY/S9aMwnKJXII/AAAAAAAADeE/RwNFnf7g0zc/s400/P4261428.JPG

Hella micro DE's with ddmtuning hid raptor kit:
http://lh3.ggpht.com/_oJh5dgNo-iY/S9aMv8QNELI/AAAAAAAADd8/an9zuKG1YN8/s400/P4261426.JPG

Both
http://lh4.ggpht.com/_oJh5dgNo-iY/S9aMwaIUkTI/AAAAAAAADeA/vI6yfQsDBfQ/s400/P4261427.JPG

Both
http://lh3.ggpht.com/_oJh5dgNo-iY/S9aMxL2ckUI/AAAAAAAADeM/t8Qa3EWpbIM/s400/P4261430.JPG

Hella micro DE's with ddmtuning hid raptor kit:
http://lh6.ggpht.com/_oJh5dgNo-iY/S9aMw5vUMvI/AAAAAAAADeI/bCfU_Xf3hGA/s400/P4261429.JPG

[Haggis]

A manual T-case swap will be interesting to watch. I've not yet have gotten comfortable with the push button engagement on my Tundra. Sure it works fine, but after decades of pullin' a handle I just sort of automatically reach for the T-case lever by default. Makes for some comical remarks from the family when I'm trying to engage a lever that isn't there.

Anyways, it's good to see a thread for your truck on the ExPo, it's one of my favorites.

[dyogim]

A manual T-case swap will be interesting to watch. I've not yet have gotten comfortable with the push button engagement on my Tundra. Sure it works fine, but after decades of pullin' a handle I just sort of automatically reach for the T-case lever by default. Makes for some comical remarks from the family when I'm trying to engage a lever that isn't there.

Anyways, it's good to see a thread for your truck on the ExPo, it's one of my favorites.

Thanks! I'm enjoying the build on your rig as well. With two kids I need to get the rig set-up for family camping trips and long hauls. Thinking about lowering the rig about an inch. When these MT's wear out, if I can't get a good deal on another MT set, I'll get AT's. The 35" mickey thompson MTZ's I got for a steal at $200 for all four, used with 80% tread left. :Wow1:

The manual tcase project is taking it's time:sombrero: With the newborn and all the other house projects and smaller truck projects, it's hard to take time for the tcase. Still waiting on one particular part for the tcase. Otherwise, I'll need to tear down my stock one for the part I'm looking for. Don't want to do that since, my rig is my daily driver. So, maintenance items are on the top of the list...

[jim65wagon]

I'm "01tundra" over here......

Yeah, what's up with that? Confuse the crap outta people....

Mike, as always, that's one of my favorite Tundras....well yours and JJ, er, 01Tundras. Awesome truck and looking forward to more pics. Is it difficult to lift a car seat that high for the newborn?

[dyogim]

Is it difficult to lift a car seat that high for the newborn?

Not too difficult but, definitely harder than using the camry. Our 4 yr old hops onto the sliders and climbs in. She uses the term "rock climbing" when she does this. LOL!

[dyogim]

Recently upgraded my bench seat to buckets and a center console. Still not sure what I want to do about the center console and what I can install in it's place or what.... we'll see what happens in the next few weeks.

I think I'm finally good with my aux light changes. Added some lights to the roof rack to help light up the bed and it's surroundings better. Had a pair of the cheapo wally mart lights laying around but, wired them up using a relay and not with the kit it came with. The 12v switch for the relay is tied to the cargo light button inside the cab. This way , the lights turn on when I open the door and automatically shutoff when the doors shut. Plus I didn't have to wire up another switch. It's all controlled with the cargo button. When I first installed them, I had some LED H3 bulbs in them. They weren't bright enough so, I went back to the 55W halogens. I'll probably go down to 35W, if I can find them locally. Here's the pics. Last pic is a night shot of the LED's.



http://lh4.ggpht.com/_oJh5dgNo-iY/S_vwkOY4F0I/AAAAAAAADiE/RlAWxzHvdMg/s400/P5241455.JPG

http://lh4.ggpht.com/_oJh5dgNo-iY/S_vwjgCiLaI/AAAAAAAADiA/Fj-tqgcQ8Qc/s400/P5241454.JPG

http://lh3.ggpht.com/_oJh5dgNo-iY/S_vwgtItZAI/AAAAAAAADhc/S0lcfeToU3Y/s400/P5241443.JPG

http://lh4.ggpht.com/_oJh5dgNo-iY/S_vwhOmcA9I/AAAAAAAADhk/80uo0VZWRQk/s400/P5241445.JPG

http://lh3.ggpht.com/_oJh5dgNo-iY/S_vwhtV5LTI/AAAAAAAADho/_brApihwshE/s400/P5241446.JPG

http://lh6.ggpht.com/_oJh5dgNo-iY/S_vwh2kPesI/AAAAAAAADhs/A2BSjbC_u1c/s400/P5241447.JPG

Here's the LED bulbs. Light output is very poor. The factory cargo light is brighter. :td:
http://lh3.ggpht.com/_oJh5dgNo-iY/S_vwfQaWhxI/AAAAAAAADhQ/6MV3A87nU1M/s400/P5231440.JPG

[dyogim]

Looking at getting my hands on one of these in the near future, Smittybilt XRC10 electric winch. For now, I'll keep the steel cable and hook then, swap it our for a synthetic line, different hook and aluminum fairlead. Hopefully, I won't need a new bumper

http://www.smittybilt.com/images/products/primary/45_1.jpg

[01tundra]

That's a nice addition!

[dyogim]

That's a nice addition!

Yeah, I figured it would make it easier to pull the cars out of my parking spot at work.... less damage to the other vehicles. :sombrero:

[dyogim]

New toys for my birfday. PS3 to replace my consistently over-heating one (but it still works) and the winch. Now I need a winch plate to mount it.

http://lh5.ggpht.com/_oJh5dgNo-iY/TDdb9mUzcsI/AAAAAAAADoU/z9tPzvb1evA/s640/IMG00021-20100709-1015.jpg

[dyogim]

Current bumper has been modified and enhanced to mount the XRC10 winch. Winch is mounted but not wired. Still need to paint the winch plate and added metal. Here's some pics from my blackberry. I'll have better pics during the day. After these pics were taken, additional tabs were welded for the roller fairlead. The winch plate has been welded to the frame cross member and the two crossbars of the bumper. The lever to engage and disgage the winch was also modified for clearence.

http://lh3.ggpht.com/_oJh5dgNo-iY/TEP496xsphI/AAAAAAAADpQ/833n1aYUEac/s800/IMG00028-20100718-1438.jpg

http://lh6.ggpht.com/_oJh5dgNo-iY/TEP4-ho0AkI/AAAAAAAADpU/IJHTODAj1jQ/s800/IMG00029-20100718-1438.jpg

http://lh5.ggpht.com/_oJh5dgNo-iY/TEP4-9HyPOI/AAAAAAAADpY/Ht0Swv8Wqww/s800/IMG00030-20100718-1449.jpg

Thanks to Adam and Orlando of AnySevenOffRoad in San Leandro, CA!!!!

[dyogim]

Finally rattle canned all the exposed metal, wired it up. Only thing left to do is attach the +/- cables to the battery. Need to get some new terminals for the top of the optima. Here's pretty much the final pics:

http://lh5.ggpht.com/_oJh5dgNo-iY/TEXGXKevybI/AAAAAAAADtk/ZcQnB2eeHco/s800/P7191503.JPG

http://lh4.ggpht.com/_oJh5dgNo-iY/TEXDs7rj2PI/AAAAAAAADqc/W57MTIswnOo/s800/P7191500.JPG

http://lh3.ggpht.com/_oJh5dgNo-iY/TEXDwBi9xRI/AAAAAAAADq0/DJnXjuKRxx0/s800/P7191507.JPG

[jim65wagon]

Nicely done!

[taco chaser]

Looks good Mike, nice to see your rig is still in action.

[dyogim]

Looks good Mike, nice to see your rig is still in action.


Good to hear from you!!! Still got the taco? Still building the Adventure Trailers? If you are reading up on the Cali Forum, there's a trip planned in September for the Rubicon. The date hasn't been set but, I'm hoping to get my upgrades done by then.

Otherwise what have you been up to lately?

[taco chaser]

Good to hear from you!!! Still got the taco? Still building the Adventure Trailers? If you are reading up on the Cali Forum, there's a trip planned in September for the Rubicon. The date hasn't been set but, I'm hoping to get my upgrades done by then.

Otherwise what have you been up to lately?

The Con in Sept. sounds nice! Just set a date :drool:.
I'll PM you on the rest..

[dyogim]

The Con in Sept. sounds nice! Just set a date :drool:.
I'll PM you on the rest..

Cool. I'll let you know. Just need to swap my xfer case to a manual case.

[dyogim]

Another update. Have not been able to set a couple of hours aside for the swap. However, I did pick up another transfer case. I was in seach of a shifter lever as the one that came with my rebuild was bent pretty bad. Instead I found a really low priced xfer case that has been cleaned and has no issues.

Either case is the same case the tundra uses but, with some differences. I also removed the input shaft coupler. This is what determines manual or auto tranny application. The shorter one is for an auto and the taller one is for a manual tranny. I had an extra input shaft and I pulled the coupler off of that. At this point I'm pretty much set and ready for the swap. Here are some pics. Xfer case on the right is the one I had to fix and with the bad shifter. The left is the one I got yesterday all nice and clean. :D. Both are J-shift type of xfer cases and both are at the 4LO position. Tool on the left is a bearing puller I used for the couplers.

http://lh6.ggpht.com/_oJh5dgNo-iY/TFGw336RMcI/AAAAAAAADus/nHUq1Qt1S_E/s800/P7281526.JPG

http://lh5.ggpht.com/_oJh5dgNo-iY/TFGw4HVbvqI/AAAAAAAADuw/a5_sCbNkcKs/s800/P7281527.JPG

[dyogim]

Swap of the xfer case is pretty much complete. I still need a shifter knob a console to hide the cut up carpet and replace connectors to match for the 4HI and 4LO senosrs. Here are some pics of the swap.

Starting on the left: tundra stock xfer case, taco xfer case i recently acquired, rebuilt xfer case with bad shifter.
http://lh6.ggpht.com/_oJh5dgNo-iY/TFXyotvqlmI/AAAAAAAADwg/L0wEFEgwpkE/s640/P7311576.JPG

Beer break, Great White from Lost Coast Brewery.
http://lh6.ggpht.com/_oJh5dgNo-iY/TFXypf3P0mI/AAAAAAAADx4/JFkCRC590IY/s512/P7311578.JPG

Bearing puller tool I used to separate the coupler from the input shaft.
http://lh4.ggpht.com/_oJh5dgNo-iY/TFXypon4muI/AAAAAAAADyA/_0HmVJbjOYI/s512/P7311579.JPG

Tundra auto coupler left, taco auto coupler right.
http://lh5.ggpht.com/_oJh5dgNo-iY/TFXyp1V4Y9I/AAAAAAAADyI/yY3VZFXO9PY/s512/P7311580.JPG

Drilled a hole to locate the start of the shifter opening. Used a sabre saw and a sawzall to cut the opening.
http://lh3.ggpht.com/_oJh5dgNo-iY/TFXytDDVEjI/AAAAAAAADxM/ayMjD3fT6XY/s640/P7311587.JPG

Speed sensor. Tundra auto on the left.
http://lh5.ggpht.com/_oJh5dgNo-iY/TFXyt864hEI/AAAAAAAADyQ/8DKaCNRVrPo/s512/P7311590.JPG

Shifter access complete.
http://lh4.ggpht.com/_oJh5dgNo-iY/TFXyuE9-1QI/AAAAAAAADxY/u-heSvC80r8/s640/P7311592.JPG

Manual xfer case mounted
http://lh4.ggpht.com/_oJh5dgNo-iY/TFXyuaYpY7I/AAAAAAAADyY/e4CHVyaq_fk/s512/P8011593.JPG

Everythin bolted up from underneath. 4LO, 4HI and ADD connectors hanging. Need to replace the connectors to allow the connection to the taco sensors. ADD setup will later be removed.
http://lh3.ggpht.com/_oJh5dgNo-iY/TFXyvOhta7I/AAAAAAAADxo/ugBjjQ7muZU/s640/P8011616.JPG

Shifter installed. Need to find a shifter boot and knob to complete the swap.
http://lh6.ggpht.com/_oJh5dgNo-iY/TFXyvodmCgI/AAAAAAAADyg/L9Ajyu63uIs/s512/P8011618.JPG

Otherwise, everything works. Need to get use to shifting gears in park and/or nuetral. No longer have "on the fly" shifting of 4WD.

Now I need to test everythin all long with the winch. :devil:

[taco chaser]

Getting closer to being finished...

[dyogim]

Getting closer to being finished...

It's driveable. Drove it today and everything seems good. No weird noises, change in driveability, etc. :smiley_drive:

[dyogim]

Correction on my previous post. I can actually shift on the fly as long as the front wheel hubs are locked and both front and rear driveshafts are spinning at the same speeds. :cool:

[dyogim]

Looks like I found the issue on the erratic shifting. Looking at both the tundra auto and taco auto VSS, the tundra VSS is a tad shorter by about 1/16". Because of this, I'm thinking the speed gear is not engaging the gear in the out shaft section and causing slippage. The conditions I was experiencing was the MPH on my scan gauge would jump from 2mph, 30 mph, 80 mph and 999 mph and back down. Seriously the mph would jump around. This also caused the erratic shifting of the tranny.

Here's a pic of two VSS's: tundra on top and taco on the bottom.

http://lh4.ggpht.com/_oJh5dgNo-iY/TGI_MwoiT-I/AAAAAAAADzM/B6pOQQekjKU/s800/P8101624.JPG

I'll be ordering a VSS adaptor to allow the use of the taco VSS and connect the tundra 3 pin wire connector. Once I get it and reinstall everything, I'l post an update.

http://www.marlincrawler.com/sites/all/marlin/files/imagecache/product/vssmci200.jpg

http://www.marlincrawler.com/transfer-case/parts-upgrade/vehicle-speed-sensor-mci

[taco chaser]

Good info to know... :)

[dyogim]

Still waiting for the connector to be shipped from Marlin. I may end up canceling the order. Needed to drive my truck to work this week. So, made the tundra VSS work and matched the depth of the taco VSS.

A friend of mine reminded me that the VSS gear is pressed on. So, I pressed it out just a tad, enough for it measure the same depth as the taco VSS. Reinstalled and so far, the MPH on the scan gauge has not "jumped" around. There's still a lot of the gear pressed on and I'm not worried if it slips off. I may stick with this fix, move on and get my $70 back for the part LOL!

[dyogim]

It's been a while since I updated....

After about 3 months of driving, the erratic shifting started again and then my OD wasn't working. After doing more investigation, I thought it's the No. 2 VSS at the transmission. Replaced that from another working tundra and i still had the erratic shifting and OD still not working.

Then, the better half read somewhere that other owners had a similar issue with their OD button not working because an exposed wire in the steering column was grounding it out. Tore the column open and nothing. I started looking undeneath the truck at all the connections to look for an exposed wire. Started at the bell housing all the way down to the transfer case. What I did find was two barely exposed wires that use to be attached to the ADD transfer case. These connected to the 4HI and 4LO sensor. I had tucked the wire harness away and the exposed wires were barely touching the transfer case cross member. I taped off the ends and zip tied the harness up and away.

Test drove it and everything was working again. OD shifted in and out and no more erratic shifting. :wings: Apparently, the wires were grounding out the OD and sending signals to the 4WD ECU and causing the transmission to shift erratcically.

Moral of this story, tape off those exposed wires. :coffeedrink:

[01tundra]

Man that's weird. I'm surprised I didn't have any issues 9 yrs ago when I removed the 4WD computer and associated harnesses, ADD's, etc.

Good find, that would be a tough one to track down if those wires weren't visible.

[dyogim]

Man that's weird. I'm surprised I didn't have any issues 9 yrs ago when I removed the 4WD computer and associated harnesses, ADD's, etc.

Good find, that would be a tough one to track down if those wires weren't visible.

Tell me about it I already swapped out a bad tranny back in 04. And now again!!!!! I was thinking the worse and started my hunt for 03-04 tundra tranny. Glad it was something simple. Sometimes it takes another brain to think of the most simplest fixes...

[jim65wagon]

Great job on the wifes part finding that bit of info - never heard of that one before. See, now there's another little quirky bit of info I need to keep in the back of my skull - just in case! I hate hate hate wiring issues!

Of course, good job to you too, for actually taping the bare wires up!

[dyogim]

Pic update... Remounted my Hella 700's up top. However, I mounted them so they don't stick up higher than the basket.

Before:

http://lh5.ggpht.com/_oJh5dgNo-iY/TQEh-L2rlzI/AAAAAAAAEE4/p_vk7hpEsxA/s640/P1011108.JPG

After:

http://lh5.ggpht.com/_oJh5dgNo-iY/TQEHGGdrZ3I/AAAAAAAAEEw/5HnGh77Mw2I/s640/PC081844.JPG

http://lh5.ggpht.com/_oJh5dgNo-iY/TQEHFyaUqvI/AAAAAAAAEEQ/eK6e6_8EJn8/s640/PC081843.JPG

[Haggis]

That looks better..more streamlined and less bunny ears. :elkgrin:

[dyogim]

That looks better..more streamlined and less bunny ears. :elkgrin:

Exactly the reason I took them down in the first place... LOL!

Now to start working on my bed organization and custom canvas topper. The front end and cab have been getting too much attention.

[dyogim]

Today, I decided to drive home for lunch. I was a couple of blocks away from my house and a lady in her cadillac decided to slam on her brakes in the middle of the road. I had to slam on mine and was like "WHAT THE F*#$!!!!!!!!" As I did that, I heard a "pop" from the front end of my truck. Once the clueless lady finally realized she's a dumb@$$, she drove off. I turn into a street and try to stop at a stop sign. As I approach and press the brake pedal, it hits the floor and the truck is still moving. Now I'm saying, "OH $h!T!!!!!" Luckily I'm heading uphill to my house and have no need for brakes from that point on. Get to my driveway and look at the brakes, passenger side caliper lower mount broke and tweaked/twisted the caliper bracket. Now I need to replace two caliper brackets with beefier parts and a new caliper. Lucking I wasn't driving faster and find out I had no brakes at a red light. Here's a pic of the busted caliper.

https://lh5.googleusercontent.com/_oJh5dgNo-iY/TVSVgKOczkI/AAAAAAAAEIA/4--h4AqkVgA/s800/P1011942.JPG

https://lh4.googleusercontent.com/_oJh5dgNo-iY/TVSVgcCKYuI/AAAAAAAAEIE/gOmh22Ds5fk/s800/P1011945.JPG

[Sawyer]

Crazy!!!! Glad you are ok!!!

[dyogim]

Crazy!!!! Glad you are ok!!!

Definitely ok. Hope to have the truck back on the road in the next few days....

[Go4Lo]

Ouch! I don't recall ever seeing a caliper snap like that. Are those the TSB calipers (04-06 Tundra) or the earlier models that are prone to warpping rotors?

[dyogim]

Ouch! I don't recall ever seeing a caliper snap like that. Are those the TSB calipers (04-06 Tundra) or the earlier models that are prone to warpping rotors?

they are actually brakes made for a late 70's through 80's chevy truck. The front axle housing is a high pinion dana 44 from a late 70's Ford F150. Everything from the steering knuckles out are specific for a chevy truck.

[jim65wagon]

I've never seen that happen either.....sure would be enough to make your heart do some lumpity bumpity when you're trying to stop! Glad you're OK.

[dyogim]

Here's a pic of the busted caliper bracket:

https://lh4.googleusercontent.com/_oJh5dgNo-iY/TV8KOaoXqzI/AAAAAAAAEI4/F_J4RcTEAgY/s800/P1011953.JPG

And here's the clearence issue with the 3/4 ton caliper bracket and the 1/2 ton wheel hub/rotor. Rotor is pretty much resting on the bracket. 1/2 ton brackets are in route to be delivered this coming monday.

https://lh4.googleusercontent.com/_oJh5dgNo-iY/TV8KOja6ZpI/AAAAAAAAEI8/fMsPk_3eem4/s800/P1011954.JPG

[dyogim]

Truck is back on the road rolling. WOOHOO!!!! While replacing the caliper brackets and calipers, I replaced the pinion seal, pinion nut and washer, wheel hub seals, repacked wheel bearings, axle shaft bearings, and hubs with grease, another bead of RTV sealant on the diff cover, new coat of paint on the diff cover, steering knuckles, calipers/brackets, and leaf springs. Pics below.

In regards to the carnage, here's what I think happened. When I slammed on the breaks, the load caused the caliper brackets to collapse. This caused the caliper to bind and break at the lower mount. This caused the pin to shear then splitting the caliper bracket apart. It's like a complete cycle.....Happier with the beefier brackets.

https://lh4.googleusercontent.com/_oJh5dgNo-iY/TWvTB0ZhQyI/AAAAAAAAEKk/qNVHFwNF7nY/s800/P1011959.JPG

https://lh5.googleusercontent.com/_oJh5dgNo-iY/TWxme2j9vpI/AAAAAAAAEK4/OQIxqusAYj0/s800/P1011964.JPG

[dyogim]

It's been a while since my last update and post but, since my last post my family and I have moved into a bigger house and most of my time has been spent working on the house. I now have more than twice the size of my old house, RV parking (for the truck) and a 3 car garage where the 3rd car port will be my little shop. Going to be installing some suspended shelving to keep the storage boxes off the ground and only keep what I need on the floor.

Otherwise, updates on the rig. Getting some new wheels and a set of 37" tires. Wheels are going to be 8 bolt H1 (HMMV) beadlock wheels recentered to fit the toyota 6 lug pattern of 6x5.5 with a BS of 3". Tires are going to be Goodyear military tires also found on the H1 (HMMV) 37x1250x16.5. Once I receive the tires, I'm going to groove the lugs to have it look similar to the goodyear MTR kevlars. Where the outside lugs are siped and the inside lugs are spaced/grooved out more. The pic of the hmmv wheel shows a pressed center, mine will be flat. The tires will only have 2 of the 4 lugs in each row grooved and the other 2 siped. I'll be doing the grooving and siping myself. Fun....

http://www.trailworthyfab.com/images/D/d-17540-04.jpg

http://www.trailworthyfab.com/images/D/groovy4.jpg

Other than that, I need to replace my rear wheel bearings and at the same time, repalce the inner and out seals and o-rings. Update pics with the wheels and tires will be posted once I have them mounted on the rig. Hope to make the Overland Expo in Hollister this year....

[Derek24]

Thats going to look good! Can't wait for updates. Also, I might see you in Hollister in a couple month if everything works out!

[dyogim]

Got my bearings and inner/outer seals finally replaced a couple of weeks ago. Everything is all good. Until, driving to work yesterday morning at around 5:30am my truck felt funny. Then it started to chatter like crazy everytime I stepped on the gas. Figured my Detroit Locker was failing (still need to inspect it). Drove it home afterwork later in the afternoon and started working on the truck. Pulled the rear diff to find 2 teeth from the pinion had broken off. The 4.88 gearset was from Precision Gear and was installed onto an open carrier back in 04 then swapped onto the detroit locker back in 09. Here's a couple of pics. The pic of the AA battery is just to compare the size of the tooth chunks. At the same time, I'm trying to set-up my garage to how I want it. 3rd carport as my little shop and the 2 car port will be the camry and honda. Building shelves that will have drywall to cover the bottom, possibly with recessed lights. Sliding doors to hide everything. Thinking of using peg board. The garage has since been cleared of most of the stuff we moved. More stuff will be cleared out for donation. I've also added a futon to the shop section to the left of where the bikes are hanging.

Anyone have an open 8.4" toyota diff laying around? Gear ratio is not of concern as long as it's complete.

https://lh6.googleusercontent.com/-lQNK4CcUe1s/TlxobXSIN7I/AAAAAAAAEjk/rVoEwmZc6SY/s800/P8282210.JPG

https://lh6.googleusercontent.com/-Zu43cmgwqgM/TlxoauKDpyI/AAAAAAAAEjk/BX-YQswkg-A/s800/P8282208.JPG

https://lh3.googleusercontent.com/-uBbDj6itHdA/TkMdck0NA7I/AAAAAAAAEdA/VgPlKDe4Bdg/s800/P1012179.JPG

https://lh6.googleusercontent.com/-lvxOfABntEk/TlxoaV-IatI/AAAAAAAAEjk/RxyMmPbRAeE/s800/P8282206.JPG

https://lh6.googleusercontent.com/-3KrtbukI7kA/TkMdbEqCuvI/AAAAAAAAEdA/S_7I_kT899M/s800/P1012171.JPG

[dyogim]

New gears are installed and set. Next was to work on my recentered H1 8 bolts and 37" goodyear military tires.

Here's the recentered H1 8 bolts. Painted/primered with rusto primer and gloss black. 2 Middle lugs of the tires were grooved. Had to put my old wheels/tires on because of some brake issues. My rotors may be warped and with the larger tires, the pedal is pulsating like crazy and has made the truck shutter when braking to a stop. New rotors are on their way...

https://lh5.googleusercontent.com/-xj1i6NbvLRg/TnoIZppw-pI/AAAAAAAAEuM/vwjSyRpGjeQ/s512/P9202233.JPG

https://lh3.googleusercontent.com/-uH54p4JQC88/TnoIZxzhZwI/AAAAAAAAEuM/WE3qPlpZVic/s800/P9202234.JPG

[Derek24]

Looks good Mike! Mean looking!!

[jim65wagon]

http://www.trailworthyfab.com/images/D/groovy4.jpg

...

Groovy!
.
.
I love siping and grooving, it's a fun way to pass a few hours. Makes my hands ache a bit, but that maybe just some old age setting in.
Truck looks ready for anything!

[dyogim]

Groovy!
.
.
I love siping and grooving, it's a fun way to pass a few hours. Makes my hands ache a bit, but that maybe just some old age setting in.
Truck looks ready for anything!

That picture is from the company. I opted to not groove the outer lugs. I'm thinking with the outer lugs grooved, it could caus more chunking when off the beaten path.

[dyogim]

New brakes rotors replaced with Summit Racing cross drilled/slotted rotors. Next is to replace rear brake drums and shoes.....
https://lh6.googleusercontent.com/-zp6Edlgwu88/ToKc731oOUI/AAAAAAAAE2M/EbPAiHmehM8/s800/P9252236.JPG

Difference between the 37" Goodyear Military OZ tires and the 35" mickey Thompson Baja MTZ's. The tread width is slimmer on the Goodyears by about an 1.5". Overall width is the same at 12.5".

https://lh4.googleusercontent.com/-2pYEkf4a9HI/ToKc7yPGH3I/AAAAAAAAE2U/1aeSyUz0LBU/s800/P9262238.JPG

Looking forward to making the Expo event at Hollister, CA in october.

[Derek24]

Looks good Mike. I love my EBC slotted rotors, really made a difference over 11yr old rotors! Looking forward to seeing you and your rig again in Hollister. Three more weeks!!

[dyogim]

Chris and I still need to register for it..... Are you staying overnight? Chris and I plan on doing a day thing on saturday.

As far as the brakes, I replaced the drums tonight. After a test run, looks like my brake issues are no longer and the cause of the brake pedal pulsating and the truck shuttering was from warped drums. I can now enjoy driving again with the big ole 37's and being able to stop smoothly.

[Derek24]

Most likely just for the day on Saturday. The longer I stay the more money I will spend...

[01tundra]

Those wheels and tires are looking saweet Mike :ylsmoke:!!!!!!!

[dyogim]

Those wheels and tires are looking saweet Mike :ylsmoke:!!!!!!!

Thanks! Next is to add about 1000 airsoft BB's to each tire. Hopefully this will help with the balancing.

This will give me the opportunity to use the ether (starting fluid) method of setting a beed. Who knows, I might burn more of my eye brow/lash hairs. LOL!!!

[dyogim]

Scored a camper shell for $50. It's not in mint condition but it works and needs a little TLC. Plan on painting it flat black or spray on liner. Not sure yet. It's not exactly what I was looking for but, for the price, I couldn't pass it up. It's made by Raider. Needs, the rear door shocks to be replaced, new locks. Otherwise, in decent condition. Side windows open and close, front access window works fine. No broken glass, no major structual cracks to the fiberglass... After cleaining up and painting, I'll be looking at getting some electrical lift actuators. Looking at doing something similar to the EZ Lift camper shell system but, not spend $1300 for it. I'll also look at building some storage spaces and a sleeping platform.

https://lh4.googleusercontent.com/-RpI1cZtrh5g/TuE7zy_Lq-I/AAAAAAAAFAs/LyucFXkQMAw/s720/P1012327.JPG

https://lh3.googleusercontent.com/-g0KdENSdPi8/TuE7zizHi6I/AAAAAAAAFAs/n16x-EO2QgA/s720/P1012325.JPG

https://lh4.googleusercontent.com/-Do0H7ogXNdQ/TuE7zmjQ-qI/AAAAAAAAFAs/CImev5Bos_I/s720/P1012329.JPG

[01tundra]

Look at all those dents....fix your junk :)!

[Jnich77]

Scored a camper shell for $50. It's not in mint condition but it works and needs a little TLC. Plan on painting it flat black or spray on liner. Not sure yet. It's not exactly what I was looking for but, for the price, I couldn't pass it up.

I got mine the exact same way, not 100% what I wanted.. but close enough to work. I got main painted to match for 350.00 at a local body shop.

[dyogim]

Look at all those dents....fix your junk :)!

What dents.... LOL!!! Those will forever be scars...


I got mine the exact same way, not 100% what I wanted.. but close enough to work. I got main painted to match for 350.00 at a local body shop.

I'll have to check around. Don't think I'll have it painted to match as I anticipate scracthes from the trees and bushes on the trail. Simpler maintenace will be either rattle can or Line-X...

[Derek24]

Sweet! Looks good Mike! I would just bedline the shell, like you said it will be easier later on when touch-up is needed. I like how high the roof is. Now comes even more time thinking about what to do with the bed. I'm still trying to figure it out myself. Oh, and that shell is going to come in handy when you join us on an expo trip to the Expo Event in Flagstaff next year!!

[dyogim]

I've narrowed my search for what I will paint the shell with to the duplicolor TR250 aerosol truck bed coating. Instead of the Duplicolor BAA2010 aerosol product. The TR250 looked to be a bit smoother when sprayed on and after curing. The BAA2010 looked more textured. Since, I don't see myself walking or throwing stuff to store on the shell, the TR250 should work well. Hoping to prep the surface some time this week. I'll post up pics of the process as I go.

[Haggis]

I used the TR250 to coat the interior of my Jeep's hardtop...my wife and I couldn't stand the white gel coat. It's been about three years since I applied it and it has held up very well. I though I'd post some pics so you could see the finished results...

http://i246.photobucket.com/albums/gg105/haggis65/100_2813a.jpg

http://i246.photobucket.com/albums/gg105/haggis65/100_2814a.jpg

http://i246.photobucket.com/albums/gg105/haggis65/100_2815a.jpg

I did get a few scratches where a hard piece of gear rubbed through the coating (3 coats applied) but it was real easy to touch up.

[dyogim]

I used the TR250 to coat the interior of my Jeep's hardtop...my wife and I couldn't stand the white gel coat. It's been about three years since I applied it and it has held up very well. I though I'd post some pics so you could see the finished results...

http://i246.photobucket.com/albums/gg105/haggis65/100_2815a.jpg

I did get a few scratches where a hard piece of gear rubbed through the coating (3 coats applied) but it was real easy to touch up.

Is the texture after you sprayed the TR250 or is that how the surface was prior? If it's after the spray then, that's definitely what I'm looking to achieve. Appreciate the pics!

[Haggis]

That's the texture after spraying.

[Blender]

Sweet! Looks good Mike! I would just bedline the shell, like you said it will be easier later on when touch-up is needed. I like how high the roof is. Now comes even more time thinking about what to do with the bed. I'm still trying to figure it out myself. Oh, and that shell is going to come in handy when you join us on an expo trip to the Expo Event in Flagstaff next year!!

Tundra invasion at overland expo? Sign me up.

[dyogim]

Just scored me a Tuffy Lock box deluxe model console for $40. Just need to go pick it up from the guy. This will replace my current stock console and will be a nice spot to carry my glock (soon to be in my name). Here's a pic from the tuffy website. The one I'm getting is black, in used condition but, still in decent shape.

http://www.tuffyproducts.com/images/product/large/104_2_.jpg

[TACODOC]

Nice scores!

[motochain]

Tundra invasion at overland expo? Sign me up.

I'll be there!



Dyogim, are you scoring all these parts off craigslist or where are you finding this stuff?? (camper shell, Tuffy, etc.)

[dyogim]

I'll be there!



Dyogim, are you scoring all these parts off craigslist or where are you finding this stuff?? (camper shell, Tuffy, etc.)

All off of craigslist. Just scored a IFS steering box in trade for my modified hella 700's (although they were modified back to halogen bulbs). Going to commit to getting my hydro assist steering set-up this year. My plans for the lights are to get a pair of the 24W DDM tuning LED flood lights. Then start building my storage/sleeping platform for my bed. Trying to make the set-up buildable and collapsible within minutes. While being adjustable depending on my storage needs.

[dyogim]

Here's the tuffy deluxe lockbox I got for $40. In great condition and the keys still work. I'll need to remove the armrest on the driver side but that's not a big deal. I'll post more updates after install.

https://lh5.googleusercontent.com/-nc1a6_GJZHQ/TxRrlcMPrfI/AAAAAAAAFCs/W7cG4ZsSOB4/s800/IMG-20120114-00044.jpg

[Haggis]

Then start building my storage/sleeping platform for my bed. Trying to make the set-up buildable and collapsible within minutes. While being adjustable depending on my storage needs.

This is what I came up with for my Tundra....

http://farm6.static.flickr.com/5207/5350771904_80334b0658.jpg

Here's the driver’s side box set in place. It is held in place by fasteners that utilize the factory tie down points in the bed.

http://farm6.static.flickr.com/5284/5350791580_2fbaee8141.jpg

Both boxes installed with my 25 gallon water tank in place. The boxes were built to match the height of the water storage crate, this way the crate acts as part of the sleeping platform. I want the tank to the front of the cargo space to keep the weight centered in the truck. The hose is run back towards the rear so it is easy just to tug out the hose and spray away.

http://farm6.static.flickr.com/5010/5350180985_8c343c00b6.jpg

Next shot is of the fridge installed. This photo is of the test fit, now there is a frame work that bolts in and out this provides a cradle and lashing points for the fridge. The end of the storage/sleeping boxes was left open to allow easy access to items that are used regularly. The driver’s side alcove holds cooking utensils, stove and housekeeping items, the right holds the food stuffs and potable water.

http://farm6.static.flickr.com/5046/5350796074_00bf5fb007.jpg

When not using the water tank I made two panels to fill in the space of the missing items. That way I can run without the water tank or fridge or just one or the other. truck.

http://farm6.static.flickr.com/5201/5350185937_bddd1d8555.jpg http://farm6.static.flickr.com/5005/5350184207_dfdc207bdc.jpg

[dyogim]

Nice build Haggis! The two side boxes are what I'm looking at doing but having it adjustable. Hopefully, soon. My son is in the hospital. So, everything is on hold....

[motochain]

All off of craigslist. Just scored a IFS steering box in trade for my modified hella 700's (although they were modified back to halogen bulbs). Going to commit to getting my hydro assist steering set-up this year. My plans for the lights are to get a pair of the 24W DDM tuning LED flood lights. Then start building my storage/sleeping platform for my bed. Trying to make the set-up buildable and collapsible within minutes. While being adjustable depending on my storage needs.

I've been checking out those flood lights also! They'll be a nice addition.

[dyogim]

I've been checking out those flood lights also! They'll be a nice addition.

I ordered them and when I checked on the status they are being shipped from China. In the meantime, I'll see about bolting the tuffy box down.

[motochain]

Bummer they're not already in the US, but I'm always amazed at how quickly items can cross the water from China. LOL. Where are you mounting the lights?

[dyogim]

Bummer they're not already in the US, but I'm always amazed at how quickly items can cross the water from China. LOL. Where are you mounting the lights?

for now, probably to my front bumper. I got rid of my Hella 700's so, i can place them there. I may try to mount them to the rack when I remount it using better mounts. The rack will be more low profile and won't have rivots that will wear and rattle the rack.

[dyogim]

Got the tuffy lock box installed. I repainted it with a coat of the dupli color truck armor paint. Rremove the front drink tray and mounted it to the rear of the box. Ssecured the box using some self-tapping bolts. Removed the padding and will re-upholster it later. Lastly, I decided to remove the pass. side arm rest instead of the driver. This was needed because, the lid would not open if both armrest were there.

After I ripped up the upolstery and padding.
https://lh4.googleusercontent.com/-8q6dBV111sA/TxvS1qyO4vI/AAAAAAAAFDw/Y0Y6OLgkfU8/s640/IMG-20120121-00007.jpg

After paint
https://lh5.googleusercontent.com/-gD1NX2Be36k/TxvS0wpS0hI/AAAAAAAAFDw/wTvEkgoXEMA/s640/IMG-20120121-00008.jpg

Close up of the texture:
https://lh6.googleusercontent.com/-JxFVjW5EgaY/TxvS0okMJOI/AAAAAAAAFDw/JHjlGgKXt0U/s640/IMG-20120121-00009.jpg

Installed:
https://lh6.googleusercontent.com/-s_T6zWIDxnk/TxvS2mXgdDI/AAAAAAAAFDw/2aVqb0Jph_k/s640/IMG-20120122-00011.jpg
https://lh4.googleusercontent.com/-CF3nlfmQSq0/TxvS2d4PE7I/AAAAAAAAFDw/U3S_rwVHLf8/s640/IMG-20120122-00018.jpg

[Petrolburner]

Lookin' good!

[dyogim]

Finally got the DDM Tuning FX series 24W led flood lights today. Got home and installed them. The lights are set-up with 2 wires, black and red. Black is ground, red is power wire. Install was simple and straight forward. I used the power wire from the previous hella 700 lights and then ground was connected to a local bolt. Here a couple of pics mounted and night shots against the garage door. I'll get more pics later and better comparison shots projecting out further as I still need to make adjustments. Still unsure I want them mounted on the prerunner bumper.....

https://lh4.googleusercontent.com/-QhURYsGW74c/TyJH2c7o-_I/AAAAAAAAFFA/tksQUndjI80/s720/P1262336.JPG

DDM Tuning FX 24W LED only:
https://lh3.googleusercontent.com/-vUwehbEk8j4/TyJH2c6zyqI/AAAAAAAAFFA/GsQqSWAches/s720/P1262338.JPG

Headlights only:
https://lh5.googleusercontent.com/-YY2MCpBhvpU/TyJH3UBN36I/AAAAAAAAFFA/viQwz9vQoUk/s720/P1262339.JPG

Both:
https://lh3.googleusercontent.com/-OLrTatcpGpU/TyJH3VSHhQI/AAAAAAAAFFA/bSah4tHKtRY/s720/P1262340.JPG

[01tundra]

Center console turned out good Mike!

You've sparked my interest in those lights, let us know what you think about them after you use them some. I'm debating on getting a small set to mount in my front bumper somehow......

[dyogim]

Center console turned out good Mike!

You've sparked my interest in those lights, let us know what you think about them after you use them some. I'm debating on getting a small set to mount in my front bumper somehow......

Definitely! So far, I'm impressed by the amount of light and I didn't spend an arm and a leg for them. I'll try and head out tonight to a dark lot or field to get better night shots and comparison shots

[TangoBlue]

Nice job.

Are the lights mounted on the bumper round and pointed down, or are they actually oval shaped? Are the lights in the garage off or on?

I have the DDM Tuning floodlight on my rear bumper as a work/back up light. Interested in your follow-up night shots.

[dyogim]

Nice job.

Are the lights mounted on the bumper round and pointed down, or are they actually oval shaped? Are the lights in the garage off or on?

I have the DDM Tuning floodlight on my rear bumper as a work/back up light. Interested in your follow-up night shots.

They are oval and pointed outwards a little. The garage lights are on and I didn't even think about it until I later. The night shots tonight will distinguish the lights better.....

[dyogim]

Here are the additional night pics. The yellow sign to the reflecting signs where the road leads to is 500 ft. First pic is with stock headlights, second is with both stock/led and the third is led only.

https://lh5.googleusercontent.com/-KwCowRZ2Sfk/TyeGrb6UUxI/AAAAAAAAFGY/-b1mwIoSLwI/s800/P1302350.JPG

https://lh6.googleusercontent.com/-OlxB80shXWs/TyeGrea9ylI/AAAAAAAAFGY/c2REfKeiRjE/s800/P1302351.JPG

https://lh4.googleusercontent.com/-bTK2H7H2G_k/TyeGrDf4wpI/AAAAAAAAFGY/CcLJAbNtWVI/s800/P1302352.JPG

[01tundra]

Great pictures! They really light up well. Which model did you get?

[dyogim]

Great pictures! They really light up well. Which model did you get?

I got the 24W flood FX Series led.

[dyogim]

Finally bit the bullit and purchased the PSC cylinder assist kit. Kit includes rebuilt steering box drilled and tapped for hydraulic assist. 1.5" x 6" ram with all the lines and brakcets to fit. At the same time, I'll be upgrading my tierod from 1.25" DOM to 1.5" DOM (0.25" wall thickness). Instead of TRE's, I'll be running 3/4" heim joints. I have a spare steering pump and resorvoir to swap out. Will also be looking at getting a oil cooler and integrate a fan to help keep the PS fluid temps down.

Reason for the upgrade is becuase my current box, after 8 years of use is finally going bad. So bad that it's making the front wheels/tires wobble and making the whole truck shake. It sucks! I'll update with pics once available. Here's the kit

http://www.pscmotorsports.com/media/catalog/product/cache/1/image/9df78eab33525d08d6e5fb8d27136e95/p/-/p-582.jpg

I also sold the camper shell. Instead of putting too much work into it, I'm going to look for one that i want and that is one of those utility type shells. All aluminum and all three doors open outwards. I would opt for not having storage boxes where the side doors would open. I've seen a few in the area....

[01tundra]

Man.....I've always wondered how you made it this long without ram assist :)! When I first did the SAS on my Tundra it had 33's on it and it was a bear to turn the wheels while sitting still.

You'll love the ram, just be carful when routing the hoses, I had one rub through (my fault) on the edge of the frame. Use a lot of zip ties and also think about using larger O.D. hose split and zip tied over the hoses wherever contact could occur.

Let me know if you need any pictures of how I routed mine, most are probably in my build threads. But since I had two different style boxes and about four different rams on it over the years, I kind of learned stuff the hard way.....trial and lots of error :D!

[dyogim]

Man.....I've always wondered how you made it this long without ram assist :)! When I first did the SAS on my Tundra it had 33's on it and it was a bear to turn the wheels while sitting still.

You'll love the ram, just be carful when routing the hoses, I had one rub through (my fault) on the edge of the frame. Use a lot of zip ties and also think about using larger O.D. hose split and zip tied over the hoses wherever contact could occur.

Let me know if you need any pictures of how I routed mine, most are probably in my build threads. But since I had two different style boxes and about four different rams on it over the years, I kind of learned stuff the hard way.....trial and lots of error :D!

Yeah, it was definitely difficult on the trails. I've had several occasions where the steering wheel would spin from hitting a rock/ledge and give me burns on my hands from rubbing. I started to wear gloves when wheelin'. I'll look through the build thread and see what I can find before I have you send pics. Didn't you have the 8" stroke and then downgraded to the 6"?

Kit is scheduled for delivery on the 22nd. Looks Like I'll have to use my spare steering box just to have the truck driveable for now. I want to at least have the new tie rod cut down, bungs and tabs for the ram welded in. That way, When I get the kit, it'll be "plug and play". Of course that's never how it goes. LOL!

[01tundra]

Yeah, I ended up with a 6" PSC ram like you ordered, worked well. I had the original 8" Howe ram limited to approx. 6" of stroke.

[dyogim]

Finally got the PSC kit delivered. Got home around 5:30pm and had to do the normal stuff before I can get to the truck parts (clean house, feed the kids, etc...). Fast forward to 10:30pm, I head out to the garage and remove the steering box. Test fit the new box with the fittings, and the freaking core support is in the way. Which I new was going to be an issue anyways. So, after work tomorrow, I'll break out the cutoff wheel and the BFH to get the new box to fit..... more updates as they become available.

[01tundra]

I had to remove quite a bit of the core support on the driver's side to clear the original Toyota box, wheeled it hard for 10 yrs with no ill effects :ylsmoke:

[dyogim]

I had to remove quite a bit of the core support on the driver's side to clear the original Toyota box, wheeled it hard for 10 yrs with no ill effects :ylsmoke:

Any pics of that "mod"? Looking at it last night, the sleeve the bolt goes through for the core support could get in the way. I'm going to try and drill some holes to feed the line and the 90 degree fitting. Hope everything clears...

[dyogim]

More updates...

A nice new air vent has been added to the core support.....Pics below. Also on it's way for delivery is a new power steering pump, oil cooler, 60 degree fitting, borgeson u-joint and 3/4"DD shaft.

90 degree fitting is not going to work well. So, I ordered a 60 degree fitting to have the line come out the new "air vent"
https://lh5.googleusercontent.com/-0Ql0xg-KzBI/T0aE0cihbyI/AAAAAAAAFH0/2ONIbou4i1Y/s600/IMG-20120223-00038.jpg

Steering box mounted. Ready for pitman arm steering shaft and all the plumbing.
https://lh4.googleusercontent.com/-WdugZvZ3ans/T0aEz_fin8I/AAAAAAAAFHs/rc9sLZXg6zc/s600/IMG-20120223-00037.jpg

credit card width between steering box and core support sleeve.
https://lh5.googleusercontent.com/-2K1EWPMwLNw/T0aEzrt4awI/AAAAAAAAFHg/lCXeKpJO_7Q/s600/IMG-20120223-00036.jpg

Once everything is mocked up, I'm going to clean up the edges a bit and spray some truck liner from the can.

[01tundra]

I'm pretty sure I used a sawzall and cut out half of the side of the sleeve.

[dyogim]

Finally got the power steering system bled, PSC steering box installed, steering pump replaced, new borgeson ujoint and lower steering shaft replaced. Added a hayden tube/fin oil cooler and integrated a fan to it for the those slow moving trail runs. Also, drilled out the pressure port to allow more fluid to pass through.

First impressions after the test run, I'm happy. I can actually turn the wheel at a stand still with one hand. Imagine when I actually get the cylinder assist put on!!! Not sure what the major factor is to result in a stock like turning feel but, I'm not complaining. Here are a couple of pics after the test run through the neighborhood. Next update should have pics of the hydro assist completely installed....

https://lh6.googleusercontent.com/-Ei2xJWucrtM/T03NX6mNJtI/AAAAAAAAFIk/m97PZ8Ej9JQ/s800/IMG-20120228-00044.jpg

https://lh5.googleusercontent.com/-iPI6zHAXzi0/T03NYGu79vI/AAAAAAAAFIk/ET07ghkRaOc/s800/IMG-20120228-00042.jpg

[dyogim]

Had an issue last week with the cylinder. The female joint PSC sent me was the incorrect one as it was oversized. Finally got the correct one yesterday. Going to try and mount and plumb the lines this week or next. Kid's birthday party is this saturday..... So, that has to take priority :cool:. Here's a pic of the cylinder mounted to the tie rod clamp and the tabs welded. Everything ready to be bolted up.

https://lh4.googleusercontent.com/-1rBUrfSya1I/T1kTrv-oOxI/AAAAAAAAFKk/VRfAHloptU8/s912/IMG-20120308-00056.jpg

[dyogim]

Finally found the utility shell I've been looking for made by ARE. Needs a front window and the shocks for the side doors need to be replaced. Otherwise, it's structurally good. Once I clean it up, it'll be painted with Dupli color tuck bed coating. Here's some pics from the seller. Plan on picking this up today after work.

https://lh5.googleusercontent.com/-hF6JnV1dlvQ/T19aGIGBgNI/AAAAAAAAFK4/y6pGs4Llegg/s640/100_2254.JPG

https://lh5.googleusercontent.com/-hJrrUkmjDkA/T19aYQ_A8CI/AAAAAAAAFL0/e8nm3uU50OM/s640/100_2260.JPG

https://lh4.googleusercontent.com/-LhbOIufthLs/T19aHSzjwNI/AAAAAAAAFLk/yNlJOPfI5EE/s640/100_2259.JPG

https://lh5.googleusercontent.com/-BDi1QzhpShk/T19aHKU1upI/AAAAAAAAFLc/yWfMcaEOA3c/s640/100_2258.JPG

https://lh4.googleusercontent.com/-QJ82X0wahnU/T19aG2gNmwI/AAAAAAAAFLQ/Xqhz-lbCo-Q/s640/100_2257.JPG

https://lh6.googleusercontent.com/-rl60CAIPwNQ/T19aGRpla7I/AAAAAAAAFLE/wnNBz3cIpn4/s640/100_2256.JPG

[Haggis]

Nice find. I've been looking for the exact same used cap for the last year or so without any luck.

[dyogim]

I was having a hard time finding one as well and was literally looking at welders to build my own....Previous owner said this one was made for a 1gen tundra. :ylsmoke:

[dyogim]

Picked up the shell last night. Need to center it onto the bed, cut some plexy to fit in the front window, replace the shocks on the side doors and clean up the spiders inside. Once the rain stops, I'll be prepping for paint.

https://lh5.googleusercontent.com/-clBjyJyPADU/T2DTrHi4OCI/AAAAAAAAFM4/kz1buf1Zol8/s912/IMG-20120314-00060.jpg

https://lh6.googleusercontent.com/-2-sv06N2-7g/T2DTqKwVDTI/AAAAAAAAFMs/ES3PX2Lgtpo/s912/IMG-20120314-00059.jpg

https://lh4.googleusercontent.com/-KN7D8sGIwJ4/T2DTpMVjuHI/AAAAAAAAFMU/QkijmMRf8V8/s912/IMG-20120314-00057.jpg

[dyogim]

Shell has been painted with duplicolor truck bed paint. On order is a new front sliding window, shock for the side doors and a pair of LED strips from amazon. Going to see if the LED strips will be bright enough to light up the inside of the shell.

Link to LED strip: http://www.amazon.com/gp/product/B002QQ1YOM/ref=ox_ya_os_product

Pick of the painted shell

https://lh4.googleusercontent.com/-7_ueS9y5ZyQ/T2dqkLuUnTI/AAAAAAAAFNQ/CwxWT5V-_DE/s640/IMG-20120319-00062.jpg

[jim65wagon]

Looks good Mike!

[WASURF63]

Looks good Mike!

x2!

Great combo. Had one of those on my '00 Tundra with barn doors and driver side toolbox. You'll love it.

[dyogim]

Got some work done on the shell while I'm waiting for the shocks and front window from the dealer. With this new LED kick I have, I decided to purchase two 16 ft LED strips from amazon for just under $13 a roll.

http://ecx.images-amazon.com/images/I/51QeFxz2ZUL._SL500_AA300_.jpg

Amazon.com: Flexible Light Strip 300 SMD White LED Ribbon 5 Meter or 16 Feet By Ledwholesalers, 2026wh: Home Improvement (http://www.amazon.com/gp/product/B002QQ1YOM/ref=oh_o00_s00_i01_details<br /><br />https://lh4.googleusercontent.com/-nwKwaeKC5So/T3lh7FTixEI/AAAAAAAAFOY/QewH66L4ESg/s640/Tassajara-20120402-00086.jpg

Pic with no lights. In the top left, you can barely see the street light shining through the shell window.
https://lh4.googleusercontent.com/-FinoEbE-q0U/T3lh7PSCouI/AAAAAAAAFOY/Z6-DL5wgAVM/s800/Tassajara-20120402-00088.jpg

With a flourescent work shop light. Again the top left shows the same street light for ref.
https://lh6.googleusercontent.com/-QwJPHPdmAGk/T3lh75SpDOI/AAAAAAAAFOY/hHB8sbwMqgE/s800/Tassajara-20120402-00089.jpg

Here's are the LED's lit-up.
https://lh6.googleusercontent.com/-UU4iAbis-s8/T3lh7RmndFI/AAAAAAAAFOY/dr99R56y2yI/s800/Tassajara-20120402-00087.jpg

[Derek24]

That is so cool! I'm ordering up some today! You think those LEDs would handle being rock lights under the fenders?

[dyogim]

That is so cool! I'm ordering up some today! You think those LEDs would handle being rock lights under the fenders?

I wouldn't use them for rock lights as they are not protected. I could easily see them getting hit by rocks or debris.

[dyogim]

Finished adding the LED strips to the shell door. I added them to the top of each of the 3 doors (near the hinges):

https://lh3.googleusercontent.com/-s8QXYg0E-fY/T36d7fmzGaI/AAAAAAAAFQ0/_U53kRbFDaI/s800/P1012358.JPG

https://lh3.googleusercontent.com/-_rxbdIM9l54/T36d_ScnbQI/AAAAAAAAFQ0/LkgXhAXx5tk/s800/P1012369.JPG

https://lh6.googleusercontent.com/-6uDmCIDkqX4/T36d84YAIQI/AAAAAAAAFQ0/kEZrv9TYWoo/s800/P1012362.JPG

[Derek24]

Cool! I should have mine here in a couple of days. I got my rock lights yesterday!

[Petrolburner]

Wow those lights are awesome!

[dyogim]

Installed some of the rock lights underneath the truck. 6 in the rear and 4 in the front wheels wells. I'll get more pics tonight. Here's a pic of the rear taken with a blackberry bold

https://lh4.googleusercontent.com/-S0RsHRjMPj8/T5TS5N6zUEI/AAAAAAAAFRk/HfouY8x1RD4/s800/Tassajara-20120422-00101.jpg

[Derek24]

Those things are bright!! Mine are still sitting on my table. I did get my camper shell lights hooked up though!

[dyogim]

Those things are bright!! Mine are still sitting on my table. I did get my camper shell lights hooked up though!

Mine have been sitting on my work bench for a while. Took a good part of the day yesterday to wire it all up.

[dyogim]

Some additional night pics of the metal backing LED's from bigredkacy(P4x4).

Side shot:
https://lh4.googleusercontent.com/-wXY7XhNUwr0/T5UFO7pDIdI/AAAAAAAAFSs/gZJGjiSBPHo/s800/Antioch-Pittsburg-20120422-00104.jpg

From the front:
https://lh3.googleusercontent.com/-WsTj6tSdKI8/T5UFO-U-4ZI/AAAAAAAAFSs/PuSgfqOFUPI/s800/Antioch-Pittsburg-20120422-00103.jpg

https://lh5.googleusercontent.com/-ENe8qLj9sSI/T5UFRs9pMbI/AAAAAAAAFSs/fkjIV8RrAFs/s800/Tassajara-20120422-00105.jpg

https://lh4.googleusercontent.com/-7pVKgaefH4s/T5UFQ3-3YFI/AAAAAAAAFSs/y3HCaZNLfkw/s800/Tassajara-20120422-00106.jpg

Looking down from one of the lights in the front wheel well.
https://lh4.googleusercontent.com/-37PS02wdIPs/T5UFPC0Se6I/AAAAAAAAFSs/DglEHFP_CBo/s800/Antioch-Pittsburg-20120422-00109.jpg