'04 Taco/Durashell build

Telcobilly

Observer
Hi Folks,
This build has been rolling around my head for almost 5 years when I purchased the truck. Now that I'm back in the oilfield, the dream is coming to fruition. My preference would be a 4x4 truck, but this is the truck I have and it's paid for so I'm making the best of it with some thoughtful mods and upgrades.
Firstly I swapped the wheels for 15X7 Kragar Soft 8's and Goodyear Wrangler 235/75/15 A/T's. For them to clear, I installed an add-a leaf in the rear, raising it 2" and a spacer lift in the front, giving me 1.5" extra clearance.
I had Brian at Beefed Taco in Fallbrook, CA weld me some sturdy HW tube bumpers front and rear to replace the flimsy stock bumpers. I then installed a pair of 100W Hella's on the tabs of the new bumper.

Next came the Durashell 165 slide-in utility body purchased from Fleetwest in Tempe AZ. It is supposed to weigh 400lbs and is pretty aerodynamic..no wind noise, but you can feel it back there. It's stout fiberglass and stainless hardware, built in Canada. It's 67" high from the bed floor, 75" long at the bed, 110" from the front of the overhang to the doors and 62" wide at the bedrails.

Three years of OTR trucking taught me how to live in a small space and what to use to be comfortable. It's basically a flat top truck sleeper turned lengthwise. Also, If I ever replace the truck, it will be another Toyota with a 6' bed, allowing me to keep this rig.


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I put in a plywood deck with a carpet runner which raises up for easy access to my food and clothes below. The cot give a little more storage below for taller items and full access to my plug in cooler.

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Just purchased this Honda EU 2000i generator today. I think I can hold off on a portable a/c until next year..

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I'm going to install these two clear access hatches in the rear doors, saving me a $1000 with a boat hatch on the roof. Plus, I'm reluctant to hack up this shell and possibly add leaks..

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Kayak Taco

New member
Nice build, that Durashell is sweet. I already have visions of adding windows, vents, etc and kitting it out as an RV... If you don't mind, what does a bare Durashell set you back? I searched on-line, but nobody posts prices...
Thanks!
 

downhill

Adventurer
Is the Durashell a Tufport?? Looks very similar. Did you verify the weight? I think the base Tufport is listed as being 375lbs. I wish there were more options along this line. Like you, all I want is a nice sturdy over sized shell that is fairly priced.
 

Telcobilly

Observer
I got it at Fleetwest.net in Tempe AZ. I don't know if they are continuing to sell this brand or not. Ask for Dave Black there. They reduced the price by $2000, so I got it for $5300 ttl. I know that is some decent change, but this well made unit has a 10 year warranty, all stainless hardware, double wall fiberglass, so no sweating and class leading interior volume. I look at it as a long term investment, able to be moved from truck to truck and it will be a tax write-off as I'm using it for work.
 

SWITAWI

Doesn't Get Out Enough
Impressive setup. That's very cool and the shell is lighter than I figured it would be for double-wall construction. How much sag did you see with your add-a-leaf setup once you got all your gear loaded up?

Only problem I see is that we didn't get some better pictures of those bumpers (if you don't mind)! :D Well done. It's nice to see someone get to combine this hobby with making their living.
 

Telcobilly

Observer
Switawi,
Thanks for your kind words. Here are some better pics of the bumpers including the tailgate I had Brian build to replace the stolen stock one. It's in storage now as it's not needed at this time. It squatted about an inch to 1.5 inches with the shell loaded.

Here's the rear bumper off the truck:

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Tailgate and bumper on the truck

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Front bumper on the truck, Turn signals are truck trailer marker lights with the flat blade bulbs installed to allow it to flash properly.

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oliverlove

Adventurer
Looks good! Those front turn signals look like they are going to be damaged pretty quick if you hit any technical trails with the truck.
 

Martinjmpr

Wiffleball Batter
Very nice. I presume it's a 4 cyl/5 speed since it's 2wd? Nice combo. Should offer great MPG. One of the best 'exploration' vehicles I ever had was a 2wd Ford Ranger. I loved it.
 

p nut

butter
Looks like a 5-lugger, which means 2.4L I4.

Nice truck. Although a window or skylight might not be a bad idea...
 

Telcobilly

Observer
Build Continued:

Got my generator this week which came in handy for installing the hatches:

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Power strip on the left side and the cord is snaked out between the bedside and shell:

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Put in a carbon monoxide detector for extra safety:

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Hatches being installed:

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The hatches fit perfectly above the ribs.

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Very impressed with the thick fiberglass construction.

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The results, I'm pleased..

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Telcobilly

Observer
I just had a 8" clear hatch installed in the forward bulkhead as a pass through to the sliding rear truck window. This will enhance cross ventilation, a little more natural light & allow me to duct heat/air from the dash as well as running a 12v extension cord to the back. I could also put a fan in the hole to move air as well.
I'm calling this project substantially complete. There will be the purchase of a heater and a/c unit next year and small items as needed. I know I'll be rearranging things along the way til I come up with something that works well. I'm going to buy SuperSprings soon to firm up the rear.

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From inside the truck cab:
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Telcobilly

Observer
Another update. Since my last post I have done a few more things. I got the Mr Buddy round propane heater head and did some organizing.
Yesterday was very productive. I got down to Houston to visit my daughter and addressed some maintenance items. The battery was replaced as the current one was almost dead. I installed new spark plugs as the originals had 140k miles, got an overdue oil change and last but not least I installed my SSA7 SuperSprings.
I'm very happy with them! Got all of my ground clearance from the add a leaf back and no more rolling in corners. The ride is still very acceptable. I do need new shocks as my no name junk replacement (Mar 2012) are shot. Going to get some good ones in the front and hold off on the back as the new springs are doing so good, the shocks can wait.
Here are some pix of my SuperSpring install.

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The rear isn't sitting low anymore. The ride is much firmer and confidence inspiring.

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4xdog

Explorer
Looks great. I like the lines and the overall simplicity of your rig.

The idea of combustion and CO inside the (mostly) closed space makes me really nervous -- I lost a cousin to CO poisoning a couple of years ago so I'm twice careful. Promise us you'll be sensitive to the risks!

Don
 
J

JWP58

Guest
Wait. Please tell me you dont plan on running that generator inside? That thing will be a death trap...
 

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