1996 Tacoma 2wd to 4wd solid axle swap

[hackster]

Got home from Seattle with a few hours still left in the day so i headed out to the garage.

I really couldnt stand how the rear crossmember on the frame turned out so out with the plasma and 5 minutes later I was in fab mode building a new rear crossmember with some led taillights flush mounted in it. Got that welded on and began on the other side of the bed with the aluminum. Once I got that buttoned up, I made some more braces for the main bed area and got to work on building the main floor.

I used .125" 5052 aluminum and it is pretty stiff. I need to add just a bit more support to it on the outside edges, but other than that I am pretty happy with how the back turned out.

Finished up the night by getting the license plate temporarily mounted along with wiring up all the taillights as well as the lic plate light.

Here are a few pics of how the bed turned out. I plan to get the shocks on tomorrow night and hope to get a winch on and running this week.

I gotta get some mounts burned on this so I have some way to tie some crap down.

Sean

 

[skinny_pedal]

The vent tube needs to be there, or you'll play hell trying to fill the tank...:awesomework:

C'mon Kev. Only take 20 minutes to fill 15 gallons:D

 

[hackster]

So I got my warn winch yesterday. Its a new old stock m9000. However it just did not fit in the bumper at all.

I had to add some plate onto the back of the tray, notch it out and cut some access holes in the bottom to get to the bolts. It ended up fitting quite nicely though and tucks in right below the grille without any cutting.

I also mounted the control pack in behind the grille with a tab right in front of the radiator. It is tucked back in there quite nicely and you access the remote plug through a 1" hole in the very bottom of the grille. Looks super inconspicuos.

Shortened up the exhaust and got it to come out right at the back of the rig. Between the leaf sprang and the frame. I had to clean it up and throw some clear on it, I couldnt live with the rust coated dirt. Also, I got the rear shocks all mounted up finally, I have about 5" of uptravel and the shocks are still under the bed floor. I am not into having a ramp champ and this should be just enough travel for the rear.

Wheels showed up today so Ill be picking them up tonight. I might even be able to roll this thing around for the first time in a month.

Sean

 

[outhouse]

Thanks Alan... Its been too long since we have gotten together. Let me know when you get your new rig done and we'll get together for some wheelin.

Tom,

I am torn on the storage in the rear. The last truck I ran a storage box on the bed, but never really liked how utilitarian it looked. I think I am eventually going to make a trap door in the bed floor and put some storage underneath it. I really want to be able to haul my dirtbike and pedal bikes with this still, so well see if that happens.

Hows the buggy? I saw that you were doing some work to it recently, are you back on the trails with it yet?

Sean

ya its been a long while im starting my chassis next week so hopfully it dosent take too long. im hoping to have it done by 4th of july at the latest. the bed turned out rad!

 

[hackster]

Well, things went well.....

Onto the pics. New trail ready HD wheels with wide Rock Rings.

Aside from the wheels being a pain to mount with the deep flange, they are awesome. The offset was about perfect. I ended up with just the right width on the axle wheel tire combo and I cant wait to get it pulled out of the garage tomorrow.

Sean :D

 

[tomota]

I know you probably have a plan already but how about a few more leaves in the rear pack? Also please get those wheels dirty, th:cool:e bling hurts me eyes

 

[Boonie Buster]

Any updates on this thing? How does it ride?

I was gonna ask if you ever had any issues with the pitman arm coming into contact with the springs before the bump stops were put on? Looks really close, nice and low though! :awesomework:

 

[Cascade_Crawler]

sweet sean, didnt even know about this thread back in december. Fabbin is one thing I miss with the bikes.