Expedition TrailBlazer Project

[JamesDowning]

Since my off road driving has been getting slightly more intense, I wanted the assurance that a matching spare tire can provide. The decision had to be made on where to stow it.

There are two real options, roof or rear.

After reading many warnings of the dangers of adding too much weight to the roof, I decided to find a way to mount it on the rear.

As there are no rear bumper options for the TrailBlazer, I thought my only option would be a hitch-gate which plugs into the rear receiver:



However, I didn't like how it the tire stuck out so far, how it covered the rear glass, the weight, nor the price.

So I hunted around a little more and found CBI offroad fab. They specialize in toyota modifications, but they also make a lay-down tire carrier. The price was right, and they were built to the customers specifications.



It even had a pass-through receiver hitch that allowed me to use a D shackle:



And even a hilift mount:

[lexwoody]

Nice build man so far. Good choice of vehicle I might add. Looks real good.

[JamesDowning]

After going on a few longer trips, I found that I needed some extra storage. The inside of the truck was getting full (especially if I brought more than one passenger). I also needed a place to carry extra fuel in order to extend my range, and to carry my mountain bike (and maybe a kayak in the future).

So after shopping around I decided to indulge myself with a BajaRack.



At first I used the mounting system that came with the rack (below). It would be fine if my truck had a different roof crossbar, but after I had loaded it down for a test run, I found that the stock crossbars just weren't holding up like they should.



Below is the new system that is bolted to the U channel on either side of the stock rack. The new system uses a 1" square aluminum rod as the load bars. The rack is super sturdy now... 100% better than stock:



Wedco fuel cans in place but not strapped down. This was a picture from a test fitting I did.



BajaRack doesn't make a bike attachment for their rack, so I had to get a little creative with some U bolts:





I used some quick fists and some pipe clamps to mount up a handy location for the shovel:



Oh and I love gadgets... so I couldn't pass up a rear view camera, mounted to the rear crossbar:



The mini screen is mounted above the rear view mirror. Instead of wiring it into the reverse circuit, I have it controlled by a small switch on the side of my previously posted switch panel.

[02TahoeMD]

Any info on the camera? You are giving me bad ideas James. (well, not really bad....just bad for the budget )

[JamesDowning]

Haha, it's actually a reasonably priced mod (relative to the other mods) (~$80).

The camera and LCD are part of a package by Pyle called the PLCM25. I liked it because the LCD was small (2.5" diagonal), the camera was made for reverse (image is flipped left-right), and has night vision capabilities (not great).



The camera was made for flush mounting, so I had to find the offset 90degree bracket on Mcmaster. Luckily both the camera and my rack have roughly a 1" OD.


2534T29 - Steel Clamp-on Structural Framing System Open Crossover Fitting $2.92 Each

I waterproofed (more like water-resistified) the back end of the camera with some superglue. I still get some fogging after super heavy rain.

As a final word of caution... make extra certain not to reverse polarize the LCD screen wires (black wire and black wire with white line... I figured the all black wire was ground... wrong...) or the screen will transform into a 2.5" smoke bomb.

[JamesDowning]

So as the trails got more difficult, I noticed the rocks and obstacles were getting closer to the rocker panels. I hadn't yet made the mistake of body damage, and only had a couple minor scratches in the plastic. However, I realized the signs and decided it was time for some protection, and it was time to take the next step in my vehicle's ability.

I contacted a local fabricator in Manassas, VA, Freaky Tree Fabrication and we got to work making a custom set. I set out looking for a simple set of sliders, but the fabricator had an interesting concept that would follow the vehicle lines and protect the rocker ends well. So I gave him the go ahead.

Here we are doing a test fitment, the tubing is 1-3/4" DOM, 1/8" walls (same stuff that most roll cages are made of):


I've seen some people tear the lower rocker panel off the vehicle in order to mount the sliders slightly higher. Eric and I looked into this as an option. The Trailblazer has a body seam that runs directly behind the panel, and is as low as the panel (except at the ends). So we worked around those ends by incorporating this fancy artistic (yet functional) end design:



The rocker panels also hold a piece of the door weather stripping. There is an outer strip that runs along the bottom of the door. Being that I drive through mud and creeks, I thought I could use all the sealing possible.

We went for weld on, as a bolt on option would just be too much trouble for it's worth. To aid in the strength, Eric added in the corner gussets. It was amazing the difference in rigidity before and after the gussets. They had a good amount of vibration without (as in, if you hit the slider, they visibly vibrated), however once the gussets were added, the slider didn't move a millimeter.



I went for powdercoat. I'd seen brush on bedliner that just scraped off sliders, and I'd seen professional bedliners get scuffed off too. I thought a durable and smooth finish would be best for something that would be used to 'slide' over stuff. Final product:



We decided to do a load test and verify their strength. Notice the very slight bend in the tube once the full weight of the driver side was on the bar. Also notice how they stick out 1/4" from the tires. This was done so that the rocker would also guard the side of the vehicle if I needed to pivot around a tree or other vertical object.



These suckers are strong.

Here's a decent picture of it not in a garage that shows the unique shape:

[chasespeed]

Looking good man...

Chase

[winkosmosis]

I've always liked these vehicles but this is the first TrailBlazer I've seen modded for offroad! Pretty awesome.

I didn't realize they were coil sprung in the back, or the Tahoe for that matter. Pretty awesome considering the Hummer H3 has leafs. Yes, I know the platforms aren't the same but I believe they are related.

Can you also use springs from the H3/Colorado/Canyon?

Edit: Is it just me or is there no other midsize SUV with a ladder frame, IFS, and coil sprung rear axle??

[JamesDowning]

Can you also use springs from the H3/Colorado/Canyon?

I believe they use torsion bars and leaf springs.

Edit: Is it just me or is there no other midsize SUV with a ladder frame, IFS, and coil sprung rear axle??

The closest I can think of is the FJ Cruiser. It has IFS front, a decent frame, and a 5 link rear axle as the TB does.

[RocKrawler]

Edit: Is it just me or is there no other midsize SUV with a ladder frame, IFS, and coil sprung rear axle??

FJ Cruiser, every 4 Runner since 1990, I believe the Montero sport has rear coils,