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post #31 of 43 (permalink) Old 09-24-2012, 01:25 PM Thread Starter
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B, double E, double R, U-N, BEERRUN!

So I took Zilla down to the car wash to clean her up before adding a fresh coat of flat black rattlecan to the exo cage, and ended up making her innaugural beer run (under my ownership, anyway).


Had to go with a 30-rack of Key Light, in honor of MrDoug and all the fab work he put into her lately.




Hahahahaha

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734

Last edited by Stealth 4x4; 09-26-2012 at 09:53 AM.
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post #32 of 43 (permalink) Old 09-26-2012, 10:20 AM Thread Starter
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Electrical

So last summer on Carnage Canyon after I blew my front diff, when the winching went on and on trying to get up the exit, eventually the Optima yellowtop got drained to the point where my high output (160-amp) alternator started kicking out more juice to try and keep up with the electrical load. What happened was, it blew the main fusible link in the fuse box, not once, but twice. Since then, we did a little research on proper wiring schemes for high output alternators, traced some wires on Zilla, and discovered that the guy I hired to wire the new high output alternator had wired the hot lead with the wrong wire (8 instead of 4 gauge) and fed it through the fuse box (which can only take 80 amps before it blows the main fusible link) instead of directly to the positive terminal of the battery. So we are going to rewire the alternator the right way with some better 4 gauge wire, running through a 175-amp fuse directly to the battery, with an 80-amp tie-in to the fuse box so this won't happen again. There is a good write up with some wiring diagrams available here if anyone's interested... http://www.rocketcityrockcrawlers.co...%20Project.pdf

Aside from that, I need to bolt down the topper on the back of the runner before we take it out for a shakedown run this weekend. We were going to go topless, but the weather might be cold/wet enough that the little lady will appreciate an enclosed cab with the heater running. So a topless run might have to wait until I get the rig back to AZ.

With a fresh coat of paint on the exo cage, I'll be able to recognize any new rockrash and know that it will all be from me, and not one of the previous owners.


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'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #33 of 43 (permalink) Old 09-27-2012, 11:26 AM Thread Starter
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Topper and Tube Ends

Well, I bolted the topper back down for the weekend shakedown run and am finally getting around to capping the 7 open tubes that the original fabricator of Zilla's exo never capped off. I did the best I could to get the dirt and gravel out of those open tubes before trying my hand at a little welding. .120-wall 1.5-inch end caps from Trail Gear. A bag of ten end caps only cost about $5 bucks... why wouldn't you cap them?


Certainly not the most professional welding work ever, but its an improvement over open tube ends.


Front bumper tube now capped off on both sides, as well as both the front and rear end of both sliders and the vertical tube by the swing-out tire carrier. Not a huge deal, but a detail I am happy to have buttoned up, and one that didn't take long or cost much to accomplish.

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734

Last edited by Stealth 4x4; 09-28-2012 at 05:47 PM.
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post #34 of 43 (permalink) Old 10-01-2012, 12:49 PM Thread Starter
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Spring Creek and Jenny Creek Shakedown

So this weekend we took Zilla out for some camping and a few days of light wheeling to break in the new high pinion front diff and shake down the rig to see how she does with all of her new fab work.



Aside from a sticky front hub lockout, the rig performed just great. I was really holding back and trying to take it easy as best I could. Hopefully next weekend we can go run something a bit more challenging.

I opened up that sticking passenger side hub lockout and worked it loose, bolted it back on and it seems to be working just fine now. Also drained the front diff and got some new gear oil in it, and went over the rig to re-torque lug nuts, U-bolts, knuckle studs, etc. Should be good to go for next weekend, but if the new connectors come in we might rewire that high output alternator this week. Also might extend the exhaust pipe out the back a bit further if we get time. But the rig is fully functional, and seems to be doing just fine so far on the easy to moderate stuff.

More challenges to come...

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #35 of 43 (permalink) Old 10-10-2012, 02:38 PM Thread Starter
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Electrical Connectors Arrived!

Update on the Electrical issue here...

A bag full of electrical connectors, fuses, etc. came in this week. MrDoug rewired the alternator, as described above. The 175 amp Mega fuse is inside this block mounted to the firewall. No more frying the main fusible link when it comes under heavy electrical load!


The new 4 g welding wire coming in from the alternator output to the firewall-mounted 175 Amp Mega fuse block, through the front core support to the battery positive terminal.


We also extended the tailpipe out to the back of the rig, so hopefully the exhaust won't come into the cab.

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734

Last edited by Stealth 4x4; 10-12-2012 at 09:44 AM.
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post #36 of 43 (permalink) Old 10-15-2012, 09:36 PM Thread Starter
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Old Chinaman's Gulch, Colorado

We went out for some wheeling and camping in the Buena Vista area. Found a few obstacles to play on to test Zilla a little further.







Great Fall weather for wheeling.



Zilla did pretty well overall. I am still learning the limits and nuances of the rig with this new setup. Found my breakover angle and exceeded it just enough to belly out on a boulder and had to winch off. Turtled the rig on the T-case skid, though with all 4 tires spinning in the sand and it is just fine. So its solid enough now to take the weight of the rig at least.

Here are a couple of vids from OCG...

http://youtu.be/5AmDmqVGkok

http://www.youtube.com/watch?v=KMY-n...yer_detailpage

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #37 of 43 (permalink) Old 12-22-2012, 06:52 PM Thread Starter
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Flex-A-Lite Electric Radiator Fan

It's been a while since I updated this thread. Zilla has been doing great. I tried her out on some optional stuff on the last couple of runs and so far no issues until today. I was scouting out a route to a trailhead in the Bumblebee, AZ area and the electric radiator fan died on me. Am replacing it with a new fan by an outfit called Flex-a-lite.

The model is the Flex-a-lite 674. Some websites showed it as the model #400-674, but its the "S-blade" version - basically a 15-inch fan but with the shroud it is supposed to measure 16 x 18 x 4.25 inches thick. I went with that one because its supposed to be a bolt-in fit for the 1984-94 Toyota 4-Runners and pickups and because the wiring connections are exactly the same as my fan that just died. So I shouldn't be able to screw up the wiring installing it.

It is supposed to come with an adjustable temperature sensor and A/C relay, and the specs say it flows 3,000 cubic feet per minute at 19.5 amps of current draw.

Anyway, the fan should arrive in about a week. I'll post up after I've gotten it in the rig and tried it out.

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #38 of 43 (permalink) Old 01-01-2013, 11:16 AM Thread Starter
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Electric Radiator Fan Installed

Simple install... after removing part of the intake to access it, it was just 4 bolts, 3 wire connections and putting the heat sensor through the radiator fins so the unit can sense temp changes. Once installed, you just warm the engine up to your desired operating temp and turn the adjuster dial until the fan comes on. From that point on the fan will always kick on when the engine temp exceeds that setting. There is an override switch on the dash inside the cab I can use which completely shuts off the fan for deep water crossings. Simple and effective. So far its working great!




Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #39 of 43 (permalink) Old 03-09-2013, 09:38 PM Thread Starter
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Some pics from Sledgehammer taken the weekend after the big race out at KOH 2013, thanks to Sir Marlon.













I am finally getting the chance to really enjoy wheeling in Zilla. Its not a huge build, kind of an underdog compared to a lot of the truggies and buggies that wheel out here. But it has been so reliable lately, and it's been hangin' in on some challenging trails (for me). Despite its limitations, Zilla is significantly more capable than my Taco, opening up some fun trail options!

Yeah, at this point, I'm really glad I decided to rebuild Zilla.

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734

Last edited by Stealth 4x4; 03-11-2013 at 10:32 PM.
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post #40 of 43 (permalink) Old 03-11-2013, 05:49 PM Thread Starter
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Zilla needed removable mud flaps that I can put on for running between trails and camp in Moab so I don't get ticketed up there this year. Always scary when I grab the welder, but here's what I did to the rig today...





While I had the welder out, I did a bit of grinding and laid some new weld down on my driver's side slider. A post-run inspection revealed that yesterday when I came down hard on that slider it cracked the welds along 2 of the short support tubes that connect the inner slider tube to the outer tube. No big deal, just ground it all out and laid down some thick ass new beads.

So, just a bit of to get things back to normal.

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #41 of 43 (permalink) Old 03-25-2013, 11:37 AM Thread Starter
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I had Zuk rebuild my old blown third member from the front, from before I went to the High Pinion. Now I've got a spare that I can use front or rear, in case I blow one on a big trip like Moab -- I'll be able to swap in the new third, break it in and keep wheeling! Its just a spare intended to keep me wheeling if I break far from home instead of ending my trip like when I blew the front third member in Colorado a few summers ago. So I stuck with the lockrite I already had in it from the previous owner -- but its done right. Write-up by ZUK is here...

http://gearinstalls.com/johnw.htm


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'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #42 of 43 (permalink) Old 10-11-2013, 04:09 PM Thread Starter
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Toyzilla has been keeping me smiling out on the trails this year, so I've got no complaints. With the builds on these other rigs I've been wheeling with lately, by comparison I've got to pick my lines and choose my obstacles a little more carefully sometimes, but Zilla keeps getting me out and back on some fun trails!

I thought I'd post an update here since I finally upgraded the old heavy steel winch cable for some (safer if it breaks), more lightweight 12,500 lb. rated 1/2-inch synthetic winch rope. That's a nice little weight savings way out at the front on the rig, and Toyzilla could always stand to drop a few pounds!


Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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post #43 of 43 (permalink) Old 03-13-2014, 10:08 AM Thread Starter
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Racelines, Stickies and Front Springs

I sold my old steel 15-inch beadlocks and got rid of the old dried out 37 12.5 15 Creepy Crawlers and got Toyzilla some new 17-inch Raceline Monsters and 37 12.5 17 Maxxis Sticky Competition Trepadors. Slowly getting rid of the stuff that doesn't work well and replacing it with stuff that does.

Also recently added a set of 4-inch lift TG front leaf springs and tube doors. Oh and I pulled off the topper and tailgate, and shed some useless ballast like rear seats. Dropped about 350lbs of dead weight and shifted the spare tire, parts and tools forward and lower to help keep the C.O.G. down considering the lift I got out of the new front springs...

I gave the rig a strenuous shakedown out at Table Mesa and I am loving these new mods. Great visibility with the tube doors but safer than running doorless. The new sticky Treps hook up SO MUCH BETTER than the old tires. And the added uptravel in front makes it just a bit more stable - I can get a front tire a few inches higher up on an obstacle now before I run out of uptravel and it starts to lean over. I was able to get through White Line on LT for the first time, as well as drag a dead Jeep through Anaconda, including up the steep exit. Good times.

Here is how she's looking now...

Degenerate

'03 D-cab Prerunner (4wd conversion)[/SIZE]
D-Cab https://www.ttora.com/forum/showthread.php?t=115481
'85 4Runner Geared, Locked & Exo'd on 37's
Toyzilla https://www.ttora.com/forum/showthread.php?t=168734
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