frozenground
Adventurer
Cool, thanks for the comments!
Now if I can just get it up to date before we leave for NV/Death Valley... guess I better grab a fresh cup of joe
Project Serenity: an 08 Tacoma DC overland build-up
- Thread starter frozenground
- Start date
Now if I can just get it up to date before we leave for NV/Death Valley... guess I better grab a fresh cup of joe
frozenground
Adventurer
bed rack v2.0/bed rail modification
started by selecting some steel, 3x3 angle and box tube:
removing the bedside caps:
measured and cut the bedside caps, removing the overhang over the rail. once I had the fit I sanded down the edges and cleaned them up.
first cuts completed in the steel: fitting up nicely!
long cuts completed in the steel, hole patterns transferred and drilled, test fitting:
trimmed to length and shaped, starting to look good
front:
next i fabbed up the rack mounts from the box tube:
rack mounts all welded on:
Then it was time to put everything together in the bed and make sure the tonneau was gonna fit with the new system and the Frontrunner rack etc. I also needed to get the final measurements for the weatherstripping that I later used to seal between the bed rails and the tonneau rails.
pics from the mockup:
tonneau rolled up:
tonneau rolled down:
Everything fit together pretty well at that point, it is a little tight getting the header installed with the extra thickness of the steel, but it works. Much stronger and more stable than the original mounts I had made.
During the mock up and test fit, I decided to make some tie downs and weld them onto the new bedrail caps as well. Turned out sweet, and have proven to be very useful.
At that point I wanted to get them powdercoated, called around and both local shops had a 3 week wait. Well, we had a trip planned so as usual I needed it done and took them in to get Line-X'd instead.. big mistake, came out looking like melted poo and coated so thick with giant runs they wouldn't fit back into the bed. Got my money back from that fiasco, stripped the Line-X off, and rattlecanned them with Krylon. I have plans to take them out again later this winter to make some modifications and will get them powdercoated then.
started by selecting some steel, 3x3 angle and box tube:
removing the bedside caps:
measured and cut the bedside caps, removing the overhang over the rail. once I had the fit I sanded down the edges and cleaned them up.
first cuts completed in the steel: fitting up nicely!
long cuts completed in the steel, hole patterns transferred and drilled, test fitting:
trimmed to length and shaped, starting to look good
front:
next i fabbed up the rack mounts from the box tube:
rack mounts all welded on:
Then it was time to put everything together in the bed and make sure the tonneau was gonna fit with the new system and the Frontrunner rack etc. I also needed to get the final measurements for the weatherstripping that I later used to seal between the bed rails and the tonneau rails.
pics from the mockup:
tonneau rolled up:
tonneau rolled down:
Everything fit together pretty well at that point, it is a little tight getting the header installed with the extra thickness of the steel, but it works. Much stronger and more stable than the original mounts I had made.
During the mock up and test fit, I decided to make some tie downs and weld them onto the new bedrail caps as well. Turned out sweet, and have proven to be very useful.
At that point I wanted to get them powdercoated, called around and both local shops had a 3 week wait. Well, we had a trip planned so as usual I needed it done and took them in to get Line-X'd instead.. big mistake, came out looking like melted poo and coated so thick with giant runs they wouldn't fit back into the bed. Got my money back from that fiasco, stripped the Line-X off, and rattlecanned them with Krylon. I have plans to take them out again later this winter to make some modifications and will get them powdercoated then.
Mr. Leary
Glamping Excursionaire
So yer one of them independents!
:coffeedrink:
I'll apologize in advance for vomiting random Firefly quotes all over this thread...
... but please carry on. I'm really liking this build!
frozenground
Adventurer
tailgate lock and DTRL override switch
tailgate lock: I installed the basic Pop n' Lock system. Pretty straightforward, just needed to remove the tailgate backer.
Here it is installed. Cool unit, pretty secure. Not impressed with the lock cylinder itself, though. At some point in the future I may try to upgrade the cylinder with a higher quality version..
next I decided to try the DTRL "stealth" mod. This is basically just a switch interrupt to the daytime running lights, so that I can shut them off when desired.
Simple mod, but difficult contortions required to reach the correct wiring harness behind the dash (unless you feel like removing the lower dash for this. I didn't )
here's the rocker switch I picked up at Radio Shack:
Here's where I installed it, next to the hood release. You can see the two leads for the switch coming out of the cubby hole. After this pic was taken they got wired up to the switch and everything got put back together
tailgate lock: I installed the basic Pop n' Lock system. Pretty straightforward, just needed to remove the tailgate backer.
Here it is installed. Cool unit, pretty secure. Not impressed with the lock cylinder itself, though. At some point in the future I may try to upgrade the cylinder with a higher quality version..
next I decided to try the DTRL "stealth" mod. This is basically just a switch interrupt to the daytime running lights, so that I can shut them off when desired.
Simple mod, but difficult contortions required to reach the correct wiring harness behind the dash (unless you feel like removing the lower dash for this. I didn't )
here's the rocker switch I picked up at Radio Shack:
Here's where I installed it, next to the hood release. You can see the two leads for the switch coming out of the cubby hole. After this pic was taken they got wired up to the switch and everything got put back together
frozenground
Adventurer
So yer one of them independents!
:coffeedrink:
I'll apologize in advance for vomiting random Firefly quotes all over this thread...
... but please carry on. I'm really liking this build!
ha no worries, not like your going to the special hell for it :ylsmoke:
frozenground
Adventurer
some shake down pics
after I got the rack mods finished we took her out to make sure it wasn't going to come apart and dump our tent in the trail. As usual, wifey had the camera handy
zapping some prairie rats over on my buddy's place
after I got the rack mods finished we took her out to make sure it wasn't going to come apart and dump our tent in the trail. As usual, wifey had the camera handy
zapping some prairie rats over on my buddy's place
frozenground
Adventurer
RAM Mount
I went with a RAM mount for laptop mounting solution. In the future I am contemplating a netbook or tablet and mini-mount system instead which would take up less room, but for now this is working pretty good..
components unpacked:
pic of how it mounts to the passenger seat brackets, very solid.
install was simple. I ended up taking out one section of the arm to save some room, and it still has plenty of adjustment range for both driver and passenger use.
I went with a RAM mount for laptop mounting solution. In the future I am contemplating a netbook or tablet and mini-mount system instead which would take up less room, but for now this is working pretty good..
components unpacked:
pic of how it mounts to the passenger seat brackets, very solid.
install was simple. I ended up taking out one section of the arm to save some room, and it still has plenty of adjustment range for both driver and passenger use.
Last edited:
frozenground
Adventurer
rear bumper bedliner-ized
then my chromaphobia flared up again and we had to kill off the last remaining chrome on the truck, the rear bumper.. So we picked up some roll-on bedliner and wifey did a great job with the coating while I was working on the toolbox and dual 12 volt setup..
getting prepped:
First coat.. looks like crap!
But after the third coat it looks great! Here it is all re-assembled with some road dust too..
then my chromaphobia flared up again and we had to kill off the last remaining chrome on the truck, the rear bumper.. So we picked up some roll-on bedliner and wifey did a great job with the coating while I was working on the toolbox and dual 12 volt setup..
getting prepped:
First coat.. looks like crap!
But after the third coat it looks great! Here it is all re-assembled with some road dust too..
frozenground
Adventurer
some misc stuff..
re-relocated the rear diff breather as it was getting pretty dusty/muddy inside the fender. so I drilled a hole and put it here:
got some cool no step decals for the tonneau rails:
re-relocated the rear diff breather as it was getting pretty dusty/muddy inside the fender. so I drilled a hole and put it here:
got some cool no step decals for the tonneau rails:
frozenground
Adventurer
new toolbox and dual 12 volt system
took me a long time to get all this together and planned out, but definitely worth it.
new toolbox the day I got it!
collecting components took awhile...
ripped the old junk out of the truck and started laying out the interior of the new box:
sub-structure brackets all complete and painted:
test fitting the dividing wall and shelf:
drilling more holes.. pressure switch bracket completed
making a pattern for the underhood bracket plate to hold the BlueSea fuse block (thanks barlowrs!)..
test fitting the bracket plate under the hood. made this out of 16ga
laying out the shelf components, IBS relay and fuse holder (also started installing some stickers lol)
center console disassembled, running all the wiring for the battery controller module:
All remaining metal parts getting paint:
Installing the battery controller module in the center console. Made this little bracket with velcro to hold it place, worked great!
battery controller in place:
re-wiring all the old accessories to the new fuse block location:
finally time to mount the box into the bed, all brackets bolted in first..
giant wire snake creature routed up into the bed..
box mounted to bed and ready for components!
cont. in next post..
took me a long time to get all this together and planned out, but definitely worth it.
new toolbox the day I got it!
collecting components took awhile...
ripped the old junk out of the truck and started laying out the interior of the new box:
sub-structure brackets all complete and painted:
test fitting the dividing wall and shelf:
drilling more holes.. pressure switch bracket completed
making a pattern for the underhood bracket plate to hold the BlueSea fuse block (thanks barlowrs!)..
test fitting the bracket plate under the hood. made this out of 16ga
laying out the shelf components, IBS relay and fuse holder (also started installing some stickers lol)
center console disassembled, running all the wiring for the battery controller module:
All remaining metal parts getting paint:
Installing the battery controller module in the center console. Made this little bracket with velcro to hold it place, worked great!
battery controller in place:
re-wiring all the old accessories to the new fuse block location:
finally time to mount the box into the bed, all brackets bolted in first..
giant wire snake creature routed up into the bed..
box mounted to bed and ready for components!
cont. in next post..
frozenground
Adventurer
dual battery / toolbox cont..
feel like i spent a couple days living right there getting all the junk installed lol
connections to the fuse block complete, 12 circuits should be plenty of room for all my future electrical needs under the hood.
inside of box almost complete, all wiring and components in place just waiting for the battery...
wanted to add some illumination to my box o magic, so i got a couple of these 6LED modules and a switch from oznium
modifying the plate from the latch in the toolbox to accept the switch, made a g10 standoff plate to prevent interference from the latch..
switch installed:
soldering in...
connections complete, switch on!
let there be light
completed box pics
feel like i spent a couple days living right there getting all the junk installed lol
connections to the fuse block complete, 12 circuits should be plenty of room for all my future electrical needs under the hood.
inside of box almost complete, all wiring and components in place just waiting for the battery...
wanted to add some illumination to my box o magic, so i got a couple of these 6LED modules and a switch from oznium
modifying the plate from the latch in the toolbox to accept the switch, made a g10 standoff plate to prevent interference from the latch..
switch installed:
soldering in...
connections complete, switch on!
let there be light
completed box pics
frozenground
Adventurer
couple more trip pics from earlier this year
frozenground
Adventurer
front suspension
I think it was about in here somewhere that I re-did the front suspension.
Before:
After:
some pics of the process:
pickle forking the ball joint lol wut
a pain to get these out, the pivot bolt is trapped in the engine compartment and took some bending of the sheet metal to get it out..
the old and the new
new control arm in, this pic shows the taper adapter that connects the spindle to the uniball in the arm, pretty cool system..
coilover and upper arms in place, time to mount the sway bar relocation plates and brackets for the rez cans
pic of the passenger side showing the can bracket before can is attached..
drivers side all buttoned up
I think it was about in here somewhere that I re-did the front suspension.
Before:
After:
some pics of the process:
pickle forking the ball joint lol wut
a pain to get these out, the pivot bolt is trapped in the engine compartment and took some bending of the sheet metal to get it out..
the old and the new
new control arm in, this pic shows the taper adapter that connects the spindle to the uniball in the arm, pretty cool system..
coilover and upper arms in place, time to mount the sway bar relocation plates and brackets for the rez cans
pic of the passenger side showing the can bracket before can is attached..
drivers side all buttoned up
frozenground
Adventurer
rear suspension
and moving right along to the rears
before:
and after:
pics of the process:
first thing was to get the old junk out..
removing the leaf springs, always nice to have some extra hands around for this..
rear springs out.
giving the leafs a few coats of rust preventative.
had to grind the keepers off one end to get the AALs to fit into the packs
new springs in place!
flushing off the center pin..
u-bolts and Timbren bumpstops in place
time for brake lines, this was a pain because I had to remove the brackets and grind out the openings larger to fit the new lines. worked out pretty well in the end..
drilling the frame to install the rez can mounts
at some point in there we sprayed the rear axle, shock mounts and spring perches with the anti rust stuff.
rear drivers side pretty much done:
and moving right along to the rears
before:
and after:
pics of the process:
first thing was to get the old junk out..
removing the leaf springs, always nice to have some extra hands around for this..
rear springs out.
giving the leafs a few coats of rust preventative.
had to grind the keepers off one end to get the AALs to fit into the packs
new springs in place!
flushing off the center pin..
u-bolts and Timbren bumpstops in place
time for brake lines, this was a pain because I had to remove the brackets and grind out the openings larger to fit the new lines. worked out pretty well in the end..
drilling the frame to install the rez can mounts
at some point in there we sprayed the rear axle, shock mounts and spring perches with the anti rust stuff.
rear drivers side pretty much done:
frozenground
Adventurer
suspension shakedown and GPS reciever
after I got the suspension finished up and a full laser align it was time to shake her out, so we went for a drive on some washboards and rutted gravel. Fast. Any of my fellow Montanans who may have been hanging out on a ranch over by Buffalo Jump that day, you have my sincere apologies for the dust cloud :sombrero:
around that time I picked up a GlobalSat waterproof USB GPS antenna. We started using it on the laptop in conjunction with DeLorme Topo and it is working great so far. I will get more pics of the GPS puck hardmounted to the rack soon.
after I got the suspension finished up and a full laser align it was time to shake her out, so we went for a drive on some washboards and rutted gravel. Fast. Any of my fellow Montanans who may have been hanging out on a ranch over by Buffalo Jump that day, you have my sincere apologies for the dust cloud :sombrero:
around that time I picked up a GlobalSat waterproof USB GPS antenna. We started using it on the laptop in conjunction with DeLorme Topo and it is working great so far. I will get more pics of the GPS puck hardmounted to the rack soon.