View Full Version : 2006 Tacoma DD / Class 7sx build
A whole thread dedicated to my truck seems awfully egomaniacal but I'll give it a shot. :o
The concept for this build is to have a capable Class 7sx truck that will also serve as a somewhat practical daily driver. As I mentioned in another thread, I tend to gravitate towards the unreasonable. The end goal is to run the 2008 Baja 1000 and not have a DNF next to my name when it's over.
So with that in mind, here we go:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1885.jpg
We started by positioning the driver's seat to fit me. It's on sliders with 5" of play, but dead center is my setting. Everything else is built around the seat location.
http://i255.photobucket.com/albums/hh149/mjp_2/img_1898_640.jpg
Test fit of the seats with the main hoop in place.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1894_640.jpg
The rear support tubes will pass through the rear glass.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1896.jpg
The frame was boxed below the point where the rear support tubes are attached. The gas tank was already pulled when this picture was taken.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1969.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1989.jpg
I stripped the insulation off the floor and put down U/V resistant Durabak. The fumes were clearly getting to me that day. :rolleyes: When I checked the pictures the next day I noticed a bunch of thin spots. I'll get those once the truck is out of the shop and I have a better idea of what will and won't be covered by the interior trim pieces. I'd still like to keep things looking good so I'll be doing some appearance work after I get the rig back in my garage.
And before the question is asked, I'm a capable wrench but no fabricator. All fabrication work is being performed by the guys at Carroll's Rod & Racecraft in Spotswood, NJ. I can't recommend them enough.
More on the build to-date...
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2009.jpg
With the AllPro 3" leaves and u-bolt flip installed. I'll make sure I get the extended brake lines installed long before I pull the truck out of the garage.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2012.jpg
The rear bumper brackets bolt to the factory tow hitch mounts so I can swap between the offroad bumper and the tow hitch depending on how I'll be using the truck.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2015.jpg
The unfinished bumper, but it gives a good view of the dual battery boxes in the bed. The engine compartment battery is being replaced by 2 in the bed for redundancy (duh) and weight distribution. The A/C outlet is still accessible.
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Final welding on most of the cage is complete. There are still a few more tubes to go in but the bulk of it is done except for gusseting.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1966.jpg
The cage is tied to the frame through doubler plates sandwiching the floorpan and these boxes underneath.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2019.jpg
The cage is also tied into the A pillars for added overall rigidity.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2033.jpg
The side glass panes have been replaced with lexan so I'll still have use of the rear slider. That is, as long as I can reach through the web of tubes behind me to reach the slider. :rolleyes:
Bumpers and more suspension:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2021.jpg
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The rear bumper wraps around with a little sheet-metal trimming and is tucked up about as tight as possible without making it a high-clearance number.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2027.jpg
The front suspension is going to be a bear. AllPro coil-overs and UCAs, Fox bypass shocks, Light Racing jounce shocks, differential drop, limiting straps, spindle gussets, and LCA skidplates. This is one area where I'm particularly glad it's somebody else's problem to make it all fit. In this shot the truck is on jack stands to work out travel and binding issues. The rest of the shots in this post have the front on jack stands.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2036.jpg
The AllPro coil-overs and Total Chaos spindle gussets. Nothing is cranked down yet as there's still a lot of work to do.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2050.jpg
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The front bumper as it's coming together. I'll be running BudBuilt skidplates once they're available, and this bumper is designed so the skid welded to it will end where Bud's products begin.
That's all I have for now. I'll post updates every week or two. Thanks for checking out my truck! :)
It was a productive week for the guys at the shop. I always enjoy being surprised when I stop in. :cool:
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The front differential drop.
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With the diff drop in place the limiting straps could be installed. The top mounting points are welded to plates reinforcing the truck frame. The bottom tabs are welded to the Total Chaos lower control arm skidplates.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2086.jpg
The lower tabs are aligned with the bottom coil-over mounts. To reduce the chance of shearing off the attachment points, a single bolt holds the coil-over and the bottom of the limiting strap on each side.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2074.jpg
The rear axle housing is gusseted.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2078.jpg
Since this will be a daily driver I'm keeping the overhead console for the interior lights, compass, & sunglass storage. :cool: This aluminum surround makes it look a little more finished without the headliner.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2090.jpg
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Just some cosmetic stuff here. I finished the in-cab bedliner application and pulled the seatbelt assemblies from the rear doors of the access cab.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2104.jpg
The truck as it currently stands. The windshield is just there for storage at the moment and will be properly installed when the interior cage is finished.
Like I said, it was a productive week at the shop. I'm really pleased with the way things are coming out!
I've been able to fit in 2 Saturdays of work on the truck and that's been it recently. Not much to see during this update but I did have a few revelations during installation of the Jounce Shocks.
First, the pictures:
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The front installation isn't difficult but it can be time consuming. Removing the stock bump-stop brackets was a breeze, but the coil-overs had to come out to fit my drill where it needed to be. Once removed, I let the suspension droop on the limit straps and tore a CV boot. Another lesson learned, and shorter straps are on order along with the new CV boots.
As for the rears, this:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2121.jpg
changed to this:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2129.jpg
New multi-function plates will be made for the top of the springs. Since I have the AllPro u-bolt flip on the truck, the strike plates included with the Jounce Shock kit won't work. The new plates will keep the leaf springs in place as well as serve as a strike plate for the Jounce and a mounting point for a new rear shock setup.
So what's changed? The limit straps are way too long, so they'll be replaced with shorter ones. It also became obvious that space up front is at a premium, so I'll swap in some Fox 2.5" coil-overs to replace the current Walker Evans hardware. I was originally considering bypass shocks in addition to the coils but it's just too tight.
Next Saturday I plan to install a rear-disc-brake conversion kit from TundraRacing.com. I also have some stereo upgrades that I'll be installing soon, but functional items need to be in place first.
As always, thanks for checking out my build!
The season has finally caught up with me and I woke up not feeling well this morning. Installing the rear disc brake conversion kit can wait until next week.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2132.jpg
The truck has power again! At least, the electrical system is back online. The dual batteries in the bed are contained in these aluminum boxes and power runs through the master kill switch seen here. Since the boxes keep the batteries from being accessible, an outlet has been included for plugging in jumper cables.
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The Shrockworks sliders were shipped unpainted and without the mounts attached so they could be made to work with the cage frame mounts. I'm really pleased with their construction and appearance.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2151.jpg
Without flash.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2149.jpg
With flash. Guess I was in-line with one of the lights. :D
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2153.jpg
The LightForce lights were mounted to the front bumper. After playing around with layouts last weekend we decided on this setup, although the mounts themselves were a huge surprise to me. Some form of protection will be built around the lights but the design is still up in the air.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2144.jpg
Here's the obligatory shot of the whole truck.
Thanks for following the progress!
It was a short but productive week at the shop. A lot of detail work was addressed but I'll just post updates on the bigger items.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2160.jpg
The Lowrance GPS was mounted. There was really no place to put this thing without having a custom mount built, so here it is.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2164.jpg
The antenna is currently mounted inside the cab with an overhead view through the windshield. We'll see how this works; if it's a problem it'll be relocated to the outside of the vehicle. I've tested it several times on the rear deck of a car and it seemed to work fine, so I'm hoping the same holds true in this position.
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Finally, the way it should have been from the factory! The Tundra Racing rear disc brake conversion is a high-quality kit using SSBC parts and includes the parking brake. I'm still getting kicked by this year's flu so I had the shop install the kit during the week. It turned out to be a good idea as the center of the rotors needed a little massaging to fit properly.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2176.jpg
She's standing on her own again! No more jack stands! :xrocker:
Aside from that, the rear support tubes were permanently welded to the frame and cage and the rear glass assembly was screwed in place. The rear bumper also got some more dimple die plate on top for appearance and strength.
The big things still on the list are the fuel cell, overhead cage tubes, cage gussets, rear bumper stinger, bed cage with mounts for spare tires, and a setup for longer-travel shocks in the rear.
I'm getting more excited with each week that passes. It might be the approaching Spring weather that has my energy up, but the thought of getting the truck back certainly contributes!
Another week, another reason for me to get excited.
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The rollcage gussets have been started. The detail work is time consuming but necessary to pass SCORE inspection. If all goes well, the cage should be completed by the next update.
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I hope 2 spares will suffice! :rolleyes: The wheels are just resting there for the time being. The rack was designed to hold both spares, allow space for the fuel cell beneath, mount the top of the rear shocks when they're installed, and to provide a flat floor for loading things into the bed.
This will be modified a bit to allow the whole assembly to be removed to service the fuel cell if/when necessary. I was originally planning on switching between the tow hitch and this setup, but I'm going to have a 2" receiver built into the custom rear bumper because the rear suspension will tie into the bed cage. It'd be a little tough to tow with no rear shocks. ;)
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The front lights are now protected. The bars in between each light looked too long when they were run down to the bumper so the bent bar at the bottom was added.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2226.jpg
And here's what I saw when I first walked into the shop.
As always, thanks for following the progress on my truck. Thanks also for those of you who rated my build! Hopefully I'll have some action shots in the coming weeks! :kewl:
I'll start by thanking 06HAOLE and his wife for stopping by to check out my build and for providing spare parts for the race! Matt, your truck is amazing! Seeing a long travel in-person was inspiring and gave me some big ideas for the future. :kewl:
The truck is getting close and a lot of the recent updates have focused on details.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2271.jpg
A rear-facing amber light is required by SCORE and I went with another LightForce light, this time with an amber lens and 50 watt bulb. The rules state that it must come on with the ignition, so I'll have an accessbile fuse in the cab so I can disconnect this while I'm driving around NJ. :rolleyes:
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Does anyone else think that on the 05+ trucks the overhead console looks like it's smiling? :D
Two parallel bars were run front-to-back for some overhead protection. Headroom is an issue for me in this truck, and while a full X would have been better from a triangulation standpoint, I wouldn't have cleared the tubes with a helmet. These will help in the event of a rollover and provide a handy place to mount the switch panel for the front lights, accessories, and switches that had to be relocated from the dash when the tubes ran through the vent on the driver's side.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2266.jpg
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More gussets on the cage. Carroll's Rod & Racecraft has their Flow waterjet online and has been cranking out some sweet detail pieces. Most of the cage has been tied together at this point but there are still many intersections left to go. (case in point, the bottom gussets missing from that last picture)
I've reigned myself in considerably regarding the rear suspension. In talking with Matt and others, and mulling things over for a few days, it's clear that the leaf springs will be the limiting factor for travel. Longer shocks won't benefit me, so I'll go with AllPro's rear Fox shocks in the stock locations. This may change in the future, but that would be a ways off and would coincide with my newfound long travel dreams. :cool:
Getting down to the wire with the fabrication work. Lots of little pieces left with only one or two major items still outstanding.
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The Hi-Lift mount is in. It fits pretty nicely between the two spares in the bed, and the whole assembly can be unbolted to give me a smooth flat surface when the spares are removed. It's a functional, non-race feature that'll be applicable for 90% of what this truck will be used for. Like I tell everyone — there's not a lot of desert in NJ. :rolleyes:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2284.jpg
The cage is close. An additional cross bar was added along the floor, the harness mounting tabs are all in place, and the gussets are almost completed.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2291.jpg
And speaking of gussets, the shop has been really good about adding a touch of style where they can. It should look pretty sweet when it's all painted.
If all goes well I may have seats installed by the next update! :kewl:
Tear-down is fun, but it's tough to beat seeing things come together during the reassembly stage.
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No seats yet because the paint was still drying, but the cage is done! A few more bars were added to reinforce the rear down tubes.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2315.jpg
These plates keep water out and help hold the lexan in place. A bead of silicone from inside the cab will keep things bone dry without affecting appearances.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2325.jpg
To access the fuel cell and in keeping with my quasi-daily-driver idea, the bed cage is removable. This will allow me to swap between the fabricated bumper and the factory bumper/tow hitch/tailgate setup if I want to appear a little more stock. :rolleyes:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2338.jpg
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Speaking of tow hitches, I now have one built into the rear bumper.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2345.jpg
The driver's side CV boot tore during the JounceShock installation so I replaced the 10" limiting straps with 9" ones.
The windshield is in and things are pretty much buttoned up with the interior. I still have a couple of items that I need to handle, but by next Saturday I should be able to sit in my truck again! There's also a chance of the fuel cell box being in place. The shop is cranking through the work; it shouldn't be long before I'm rolling again! :cool:
Lots of pictures this time around. (even more-so than usual! :))
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Everything's been painted and things being wrapped up. I think the bumper looks better with the paint than it did as bare metal.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2361.jpg
The stock front bumper has been loose since the bottom was cut and a brace was removed. These braces were added to the new bumper to hold what's left of the stock bumper in place.
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The spare tires will now stay where I put them. I also have a rear license plate bracket attached to the new bumper.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2369.jpg
More paint.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2371.jpg
The interior trim pieces are going back in place. I'll put another coat of Durabak down to cover the overspray. :D
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2373.jpg
The glove box is still functional. Those GPS wires will be hooked up, tied up, and hidden. :cool:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2374.jpg
The dash is back together as well. Many switches were moved (some to the overhead switch panel) and the power mirror switch assembly still has a very stock appearance in its new location.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2376.jpg
And I was able to sit in my truck again!! The overall fit is close but very comfortable. Plenty of headroom and no visibility issues with the cage.
The fuel cell components have all been cut and it should be welded up by next Saturday. Window net templates were made and shipped out so I'll have nice, custom-fit nets that'll look good and won't flop around too much. The list keeps getting shorter!
Thanks for following my build!
The to-do list is getting shorter by the day. The truck may be running again by next week and might actually come home with me a week after that! :xrocker:
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The fuel cell will carry upwards of 70 gallons. The obvious challenge of a large, flat, shallow tank is keeping the fuel near the pump. On a steep incline or hard acceleration the fuel will shift towards the back of the tank and it's possible that I could actually run dry with 50 gallons still in the tank. The bladder that will be inserted into the tank will have integrated traps to keep fuel towards the front of the tank. Until then I'll have to keep an eye on the fuel level and be aware of angles when I'm running low.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2389.jpg
The interior is all but finished. The rear door panels are the only outstanding item and I'll have those finished and installed next Saturday.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2397.jpg
New strike plates for the rear jounce shocks were fabbed up and installed. The plates were designed so the jounce shocks will bottom out just before the shock absorbers.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2402.jpg
The rear suspension at full droop.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2407.jpg
The front suspension at full droop. I may shorten those straps slightly depending on how the CV boots hold up.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2429.jpg
On the lift and ready for some undercarriage work.
My BudBuilt skidplates arrived on Thursday and will be installed this week. Once they're in place the front bumper skid can be fabricated to match. While it's on the lift the truck will get a driveshaft hoop and some more underbelly protection.
As always, thanks for following the progress!
This week was full of surprises. :kewl:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2445.jpg
The driveshaft hoop is beefier and more complex than I was expecting.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2448.jpg
The tubes running from the differential housing to the driveshaft hoop will serve both as torque arms and mounting points for a driveshaft skidplate. A curved steel plate attached to the lower two bars will keep the driveshaft and e-locker actuator out of harm's way. The forward end of each tube will be attached via slip joint with zerk fitting so the suspension will still cycle and articulate properly.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2474.jpg
The fuel cell is bolted in place and the fuel pump is installed. In this picture the bed cage is installed to verify clearance between the front spare tire tie-down strap tab and the fuel pump assembly.
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BudBuilt skidplates are big, beefy, and fit tight against the frame of the truck. As such, a little modification was needed to make the skids work with the differential drop kit. Spacers could have been used to drop the skids down, but instead the boxes in this picture were added so all the mounting points and structural supports could be maintained. Some angled plates may be added to the front edge of the boxes to keep them from getting hung up on obstacles.
The interior of the truck is back together, and if not for a bit of unfinished stereo wiring I'd have those pictures posted. If nothing else so far has, I'm pretty sure that's the update that'll have the hardcore desert guys facepalming. :p
Thanks as always for following the progress, and for all the feedback I've received!
I drove my truck today!! :xrocker:
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The fuel cell was designed to work with the stock fuel pump and sending unit. Since I haven't modified the engine the stock flow will be plenty to keep me running, and if I ever have a problem I can stop in at any Toyota dealership and get a replacement. All that and the fuel gauge still works.
:cool:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0095.jpg
The overhead switch panel is wired and looks great. None of the switches match their labels but that can be fixed. I'm going to move a few of the switches for the sake of convenience. The momentary Start switch, for instance, has been wired into the horn for use by the passenger during a race. I'll move that to the right side so it's more accessible.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0092.jpg
The underhood relays for the front and rear LightForce lights.
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The front all lit up. I'll adjust the aim of the lights after I get the truck back and have a free evening to play. Only the headlights and center LightForce lights are HIDs. The non-HID lights are hooked up to 2-way switches on the overhead console so they can either be turned on momentarily (useful for flashing someone) or continuously.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0052.jpg
This is the NJ side of me shining through. :rolleyes: I took some Xtreme Kreations access cab speaker panels and modified them to work with the rollcage. The standard panels have the speakers mounted on a raised area for appearance, but in that configuration I couldn't close the rear doors due to interference with the rollcage main hoop. I cut the panels, flipped the raised part, and re-fiberglassed everything so the speakers are now recessed.
The cool thing about these panels is that each one has a sealed enclosure behind the 10" subwoofers to improve speaker response. Combined with the 1000 watt amplifier, the stereo sounds considerably better than stock.
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Just some glamour shots.
All that's left is:
. Fuel filler neck
. Installation of the window nets
. Completion and installation of the torque arm
. Front skid plate
The guys at Carroll's Rod & Racecraft have done way more with my truck than I ever imagined possible. Like I said at the beginning of this thread, I can't recommend them enough!
The truck will be coming home with me next week!! :driving:
The truck drives great! I still have to run it a bit and adjust the shocks, but so far everything is very solid. I've kept a dead-blow hammer in the cab to take care of any places where metal rubs the cage and at this point things are remarkably quiet.
In the coming weeks I'll be doing some cosmetic work and handling the standard modifications that everybody does. (anytime locker, anytime fog lights, etc.)
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0152.jpg
The windshield wipers are mounted again! It's more of a symbolic thing than a mod but it made me smile. :D
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0147.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0137.jpg
The window nets are mounted to the doors as allowed by SCORE Class 7sx rules. The nets themselves were custom made for my truck and mounted to allow the windows to function with them installed. The tabs have nuts welded in place so removal and installation is a matter of a few bolts.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0201.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0177.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0205.jpg
The rear driveshaft is heavily protected through plates welded to the torque arm. The forward part of the assembly is attached using a slip joint with zerk fitting for easy maintenance. Articulation should not be affected and something pretty nasty would have to happen for the driveshaft to take a hit.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0207.jpg
A shot at night with the lights on. I know...it's useless to look directly at the truck and more interesting to see what the driver can see. :p The truck could flood any area in the complex with light, so I'll try to find some bigger areas to take some pictures. Unlike this shot, those will be useful. ;)
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0167.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0209.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0214.jpg
The last fabrication piece to be installed was the front skidplate. The airflow opening is based on the team logo:
http://i255.photobucket.com/albums/hh149/mjp_2/liberatedRacing_logo_640.gif
I suppose this would be the semi-official announcement of the formation of Liberated Racing. The website is in development but I should have that live within the next 3-4 weeks. :xrocker:
Many people have gone out of their way to help make this build a reality and I can't thank them enough!
Thanks yet again to Bob Carroll, Dan Vaupel, and the rest of the crew at Carroll's Rod & Racecraft (http://www.rodandracecraft.com) for designing and building my truck. I'm currently listed as one of the Featured Projects on their site.
:welder: :D
AllPro Offroad (http://www.allprooffroad.com)'s suspension components will be carrying me through the race. I plan on upgrading to their new Fox 2.5" coil-overs in the coming months, and at that point the WE gear will serve as backups in case of breakage.
I'd been speaking with Bud from BudBuilt (http://www.budbuilt.com) since December and got one of his first sets of underbelly skidplates for the 05+ Tacomas.
The guys from Shrockworks (http://www.shrockworks.com) shipped the sliders with the mounts unattached so they'd easily be adapted to fit with the rollcage frame mounts.
Light Racing (http://www.lightracing.com)'s customer support is excellent. I had originally received an incorrect part when purchasing from a 3rd party and they corrected the problem within 24 hours.
Lastly, the support from the TTORA crowd has been humbling. Specifically, 06HAOLE, tacosupreme, ryguy, Hoss, and Stuck Sucks. Thanks for all the advice, encouragement, and parts (looking at you, Matt!)!
Ok, I'm done dropping names. ;)
I'll try to make sure future updates include at least 1 action shot so there's something more interesting than the inside of a garage to look at. :xpopcorn2
I know I promised some action shots but they'll have to wait until another update. I'm working out some interference issues with my rear suspension and am running without rear bumpstops at the moment. Kind of a bad idea when landings come into play.
It turns out not all aftermarket parts are 100% compatible with all other aftermarket parts. Who knew? :rolleyes:
The jounce shocks are designed to work with the stock leaf configuration but do not play well with the All-Pro u-bolt flip kit. Fortunately the fix is a simple one. I'm going to have some steel reinforcement plates welded onto the truck frame and will drill new holes to mount the rear jounce shocks forward about an inch. Nice and easy.
The rear shocks lightly contact the rear disc brake calipers when the axle is articulated. It's so minor that I wouldn't normally be too concerned, but any potential issue now would be a preventable failure during the race. The fix could be as simple as moving the lower shock mounts slightly inward on the axle. I'll check for possible contact between the shock body and truck frame before changing anything. Wouldn't do much good to fix one problem only to create the exact same problem elsewhere. :p
Random thought on the topic of the rear disc brake kit: bleeding that system is definitely a two-person job. As mounted, the bleeder valve is not at the highest point on the caliper and it's possible that an air pocket can form above it. Using a suction bleeder will tend to miss some of the air, but having a second person push the fluid out by stepping on the brake pedal will improve your chance of flushing all the air from the system.
Not many pictures in this update because there isn't much to see. Installed longer braided stainless steel brake lines in the rear, swapped the rear discs to the proper sides of the truck (heat dissipates out), pulled/painted/reinstalled the skidplates, and performed all the standard maintenance tasks like greasing the u-joints.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0229_640.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0230_640.jpg
One visible change I did make is to the front end. The headlights and grill didn't look quite right with the new bumper so I embraced the black & white theme and made some updates. I think it's an improvement. :cool:
That's it for now. Details and debugging are tedious but I'm glad I gave myself several months of test time. I just hope it's enough! :o
Moving ate up about a month of time. It's nice to be settled and have home internet access again!
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0422.jpg
FuelSafe will be making a bladder for the aluminum can that was built for my truck. To minimize downtime while the bladder is being made, this 22 gallon Jaz fuel cell has been installed.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0423.jpg
Before a recent trip to Rausch Creek I cut the tailpipe behind the rear-most hanger so it wouldn't get crushed on the trails.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0433.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0435.jpg
While mud makes most work on the truck more difficult, it made it easy to find areas of interference with the suspension. As previously mentioned, the disc brake conversion caused interference issues with the rear shock on the driver's side.
I tested the truck without changing the rear shock setup and found things were a bit worse than I expected. The caliper rubbed a deep groove into the shock body and actually pushed the shock into the leaf spring on the opposite side.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0442.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0439.jpg
The frame has been reinforced where the Jounce Shocks mount. Since I have to move the mounting brackets forward about an inch, I wanted to make sure everything was structurally sound before drilling new holes through the frame.
I'll have the Jounce Shocks mounted by the end of the week and expect to have the rear shock mounts redesigned this coming weekend.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0391.jpg
The front bumper and skidplates were solid. Class 7sx requires the stock bumper remain in place. It obviously hinders my approach angle but rules are rules. :o
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0386.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0407_640.jpg
Overall the truck performed great! I drove to Rausch Creek, beat on the truck, and drove it home. The issues that came up during the post-run check will be addressed and I'll be back for another round. :kewl:
I'll get to CA around Wednesday, Sept. 10th for tech inspection on the 11th. If all goes well I'll have the cage certified in a few short weeks!
If anybody will be around after that Thursday I'd like to meet a few of you and do a little testing. I figure it's a chance to get my feet wet and see what other people are running. I'll be in contact with those of you that I've already met online. For anyone else, please PM me if you'd be interested in giving a newbie some direction in the desert. :o
My aluminum fuel cell is at FuelSafe and won't be back before I leave for the trip. As a result, I won't have a chance to test with a full load and set up the rear springs properly. I plan on removing a few leafs from the packs to soften the ride...it's just a matter of figuring out how many and which ones. October is going to be a busy month!
I'll have a build update posted this weekend after having some rear suspension work done.
As always, thanks to everyone for all the help!
This update is all about fixing what I broke a few weeks back.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2512.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2508.jpg
I waffled the 1/8" driveshaft skidplate so it was time for an upgrade. The new skids are 1/4" steel and are reinforced from inside. It adds a fair amount of unsprung weight but it's better than clobbering the driveshaft.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2483.jpg
The Jounce Shocks are finally back on the truck and they're moved forward about an inch from their as-designed mounting location. To work with the u-bolt flip, boxes were made to provide a smooth striking surface. They're reinforced from inside so they don't buckle under pressure.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2523.jpg
All of the wires and lines connecting to the rear axle were run to a common point, bundled together with a cable, and run down near the center of the axle. Keeping everything in the center will help protect the lines from rocks, sticks, bushes, etc. that might kick up. Bundling them together provides additional strength in case they do take a hit, and the cable running from the cross-member to the axle will help keep things from completely ripping out if something really nasty happens.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2529.jpg
Another shot of the bundle and side view of the strike plate.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2557.jpg
The stock rear shock mounts were scrapped and these 2.5" Fox shocks were mounted in their place. The upper part of the top hoop ties into the rollcage through the truck bed.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2554.jpg
The reservoirs were too large to cleanly mount in the wheel well, so here they are attached to the rollcage rear support tubes. The tube tying the cage to the shock hoop is visible at the base of the driver's side reservoir.
Obviously I'm still running the temporary fuel cell. :o
I leave for California on September 6th for SCORE tech inspection on the 11th! Thanks yet again for everybody's continued help! I'll make some phone calls once I firm up timing and know where I'll be each day. :xrocker:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0560.jpg
Before I ever ran in the desert I had planned on upgrading the WE shocks to some 2.5" Fox shocks. The side-by-side comparison:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0953.jpg
While testing at Barstow I managed to push things a bit too hard and snapped an upper control arm. After replacing some components, the front looks something like this:
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0995.jpg
The post-mortem inspection showed more damage than I originally thought. The upper coil bucket on the passenger side took a hit and will need to be straightened and reinforced.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0996.jpg
Between repairing damage and reconsidering my suspension approach to increase durability and travel, I won't be entering this year's race. I'll be at the 1000 race as a spectator and plan to gather as much information as possible from other racers and their trucks with the intention of entering next year's season with a more realistic approach and more capable truck.
Thanks to everyone for the continued advice and support! The next few months will be spent planning and I'll pick up with the modifications with the new year.
There's been a lot of changes in the past 6 months and the breakage from last year worked to my advantage. It gave me a chance to spectate the 1000 race, see true race trucks in person, and realize what it takes to get the stock components to survive. Even if I had everything built properly, I didn't get my fuel cell back until the Monday before Christmas so I wouldn't have met the SCORE safety requirements anyway. It was a great trip and time very well spent in Mexico.
I've spoken with several racers and considered my options. Given the time and cost involved in getting the stock components sufficiently built to survive racing and the reality that I'd still only have a mid-travel truck that would beat the hell out of me compared to some people's weekend rigs, I decided to change direction and target the Sportsman class. The freedom to build a more capable truck, a chance to experience racing without getting in the way of for-profit racers while I learn how to drive, cheaper entrance fees, etc. all seem like a better fit for me. After a lot of thought it also seemed a bit silly to enter a points class when I'd only race one to three races a year.
The cost difference between completing the 7sx build and switching to Sportsman is a wash as all of the safety requirements are the same. I'd be building a new suspension setup either way.
So, given all that, here's what's been going on. :)
I bought a diesel truck and trailer to get my Tacoma to and from races. Reality is a funny thing and Barstow taught me a lot. :o Also, rather than the Baja 1000 I'm targeting the SCORE Primm 300 this September as my first race. It's relatively inexpensive to enter, in the US, and is a large loop course with a designated pit area. I'll have people in the pits with my gear and tow vehicle should I go and break something like I did last time. For communications I'll have a satellite phone if I don't have my HAM radio license and race radio by then.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1365.jpg
The stock 2-piece shifter gave up the ghost so I cut it apart and replaced the shaft with chromoly tube. Yes, I know it's mounted backwards in the this picture. :rolleyes: I snapped it before I noticed and didn't bother to take another once I fixed it. The URD short-shift kit was welded in place to eliminate any possible slop. The shifter still looks stock in the truck.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1340.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1387.jpg
Jon at AllPro contacted me about my UCAs. He heard through the grapevine that I'd broken the parts and went out of his want to contact me directly. Without hesitation he took the parts back and used my experience to improve their products going forward. That's unrelated to my build but I was just happy to see a company stand behind their product. :)
I'm currently running AllPro's upgraded steering system. The install was a snap and the parts are considerably stronger that stock.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1382.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1376.jpg
They have this pretty sweet piece that allows for a ton of wheel travel before binding.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1552.jpg
Speaking of wheel travel, I'm now running Giant Motorsports' 64" spring-under kit.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1512.jpg
Per Geoff's directions, the axle was located, the front brackets were attached, and the rear brackets were moved back 1.5" from where the spring arch would naturally have them located. The result is a preloaded leaf spring that will not suffer from leaf separation. On my truck I'm looking at about 18" of potential wheel travel once I get the right shocks mounted.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1504.jpg
The front brackets welded in place.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1500.jpg
The rear brackets were welded and tied together with square tube for additional strength.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1555.jpg
The bottom of the bed had to be clearanced for the shackles. I'll see what else I need to move/trim/cut once I have the final shocks mounted and fully cycle the suspension.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1668.jpg
I'm running a more reasonable and less offensive dust light. The Striker that had been there is now a spare for the front.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1665.jpg
I installed Glassworks fenders and bedsides. Having a white truck made it easy to not have to match paint. ;)
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1696.jpg
My plan is to start installing Camburg's long travel front suspension kit this coming weekend. The Fox coilovers in the picture are the newly designed ones announced in this thread:
http://ttora.com/forum/showthread.php?t=132315
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1698.jpg
This is a just-because picture. A stock lower control arm next to Camburg's LCA.
It's gonna be a long week if I don't start wrenching soon. It hasn't been easy having the parts but no time to start installing them!
Installing the Camburg long travel kit could easily be done in an afternoon on a 2wd truck. A combination of axle installation in the stock CVs and shipping delays while I waited on back-ordered Toyota stock replacement parts held me up for a few weeks.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1735.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1731.jpg
The tear-down went quick, and during test fitment I found that the Light Racing Jounce Shocks won't work with the Camburg LT kit as they interfere with the lower mounts for the secondary shocks.
I removed the jounce shocks and ground off what was left of the stock bumpstops.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1747-1.jpg
The inner CVs disassemble easily but the outer ones are a bit of a challenge. I cut the stock axles as close to the CV joint as possible so I could rotate cage enough to pop out the ball bearings and remove the cage.
I brought the cage to a friend's shop and attempted to press out the axle stub using a 20-ton press. When that failed, we went to his friend's shop and used his 50-ton press. That got it, but it took approximately 40 tons of pressure to pop the axle stub out.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1750.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1751.jpg
With the internal clip unseated, the axle stub easily pressed out of the cage.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1908.jpg
The new axles press into the stock CVs. I used new boots, clips, and clamps that come in the Toyota CV boot kit.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1758.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1754.jpg
My alignment cam tabs were flattened during last year's testing. In addition, the passenger side front alignment cams were frozen in the lower control arm, which meant that even if the tabs were intact, my alignment would change as the suspension cycled.
I cut off what needed to be and replaced what I cut. The tabs will be replaced and/or reinforced in the coming weeks.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1915.jpg
Reassembly was a breeze. I used a pry bar on the grooves on the inner CV cup and a dead-blow hammer to get the axle back into the differential. The hard brake lines were mounted to the frame since the old mounts on the bumpstop no longer existed.
The shock reservoir is just hanging to the side in this picture. Permanent mounts will be welded in place.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1920.jpg
Nice to see the increase in suspension travel. :)
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1923.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1928.jpg
I'll crank up the coils a bit before I have the truck aligned. Right now the coils are at 0" and the truck sits at about stock height, complete with the "Tacoma Lean" on the driver's side.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1930.jpg
The day after I finished installing the Camburg kit the truck was brought back to the shop for another round of fabrication. Lots of minor things being taken care of this time around but it's all necessary and on a timeline as the SCORE Primm 300 is approaching fast!
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1865-1.jpg
I was curious to see what the different shocks would look like side by side. The bottom is one of the Walker Evans RR shocks that I originally ran and bent to hell, in the middle is a 2.5" 3-tube bypass shock that will backup my new front coilovers, and the last is one of the 3" 4-tube bypass 18" travel shocks that will keep the rear of the truck under control.
I expect to have the truck back around August 8th. It leaves little time for test-and-tune but I'll make the most of the time I have.
Thanks as always for checking out my build! :)
I'm vehicle #1549. :)
http://www.score-international.com/261/newss/Starting_Positions_For_Primm_300.aspx
The build is wrapping up just in time! I'll post updates in the next week or so.
The long-travel conversion is still underway.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1953.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1954.jpg
The new rear shocks required new upper shock mounts for both circumferential clearance and travel. The new upper hoops will be tied together when complete.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1964.jpg
SCORE felt that the downward bends in the rear support tubes would compromise the structural integrity of the cage and requested that things be redesigned. The updates involved cutting and welding a sleeved straight tube to the end of each rear support tube. The new shock hoops provide additional support by tying middle sections of the support tubes to the frame.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1957.jpg
The factory master cylinder, power brake booster, and ABS controller are removed to fit the soon-to-be-fabricated upper shock hoops for the secondary bypass shocks. This is a change that was on the to-do list to improve braking performance with the rear discs so the timing worked out well.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1958.jpg
Removing the booster with a rollcage made for some interesting inverted wrenching. For those interested, it's held in place by 4 nuts accessible from inside the cab. :)
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2008.jpg
Since my truck is a 2006, the engine mounts needed to be reinforced.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_19662.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1996.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1995.jpg
The alignment cam tabs needed to be reinforced. Rather than simply gusseting the tabs, Carroll's Rod & Racecraft designed and cut these plates out of 3/8" cold-rolled steel on the waterjet and welded them in place to strengthen the suspension mounts.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2337.jpg
All shock mounts are gusseted on all sides for strength.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_1983.jpg
The rear shock hoops were tied into the rollcage and frame when they were fabricated. An additional tube now ties them together and provide mounts for 2 dust lights. Fire extinguisher mounts were welded to the shock hoops.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2071.jpg
The RaceAir filter is mounted behind the driver's seat and is controlled through a switch in the overhead console.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2018.jpg
Front shock hoops were fabricated to fit the 2.5" bypass shocks. The frame was reinforced where the tube attaches.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2320.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2321.jpg
The body mounts were trimmed and reinforced to clear the 33" tires.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2333.jpg
The cross-member was cut and a U was installed to clear the upper bar of the torque arm. This wasn't an issue before but the Giant Motorsports spring-under suspension allows enough travel to require the clearance.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2328.jpg
Jesse at High Angle Driveline built this trophy truck driveshaft utilizing a Ford Superduty carrier bearing and double-cardigan CV joint. It has 10" of slip and allows for 33 degrees of articulation.
A custom carrier bearing mount is required to make everything work, and its vertical placement was dictated by the clearance needed for the driveshaft skidplate at full droop.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_23452.jpg
The race radio is installed in front of the shifter. It took some adjustment but it fits without interfering with the shifter or the electronics under the dash.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_2350.jpg
The intercom fits perfectly in the center console.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_20542.jpg
Pre-race at Primm.
http://i255.photobucket.com/albums/hh149/mjp_2/IMG_0445.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/9235_535693599120_54900355_31562177.jpg
http://i255.photobucket.com/albums/hh149/mjp_2/9235_535693604110_54900355_31562178.jpg
Shots of the payoff courtesy of Derek and Martie. :)
I'll post updates on breakage and the fixes once I have time to go through everything. In my haste to finish everything in time for the race I installed the lower control arm uniballs upside down. The weight of the truck was supported by the retaining clips and the passenger side let go during the race. I'll correct that, fix the collateral damage, and have a lot of test time before I race again next year.
Considering it was an untested truck and I'm an untested driver, I'm pleased that the only breakage was minor and that nobody was injured. I'll include a full race report in my next update some time in the next 2 weeks.
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