Builds JP comes to life-Truggy Build Thread

[NCFJ]

I've been running this build thread in The Olde North State Cruiser section and it was suggested that I also run it over here. So I will get the thread up to speed over here as well and continue it as I go.

I name my vehicles, this one is named after my buddy JP.....

Now that I am in the new shop it was time to go and pick up my 83 PU that my buddy James was keeping at his house for me.

We think this cab will work for us. I like the fenders and the grill. Between this truck and the 89 Donor I have, I have the drive train I need.

Up side is that between the utility bed, cab and bed from the 89 and other parts it will cover what I have in both trucks and buy me some other parts as well.

 

[NCFJ]

I did a bit of surgery Mon night.

 

[NCFJ]

She is almost naked. None of the original frame will be used. Only the cab, fenders, hood and parts of the drive train are being kept. The entire wiring harness has been removed as well. 28 years of additions, repairs, and the wires themselves getting brittle are simply not worth playing with. A complete wiring harness from Painless will be used instead.

Very little of the interior will be reused either. A new dash will be used and the firewall and floor will also be rebuilt to accomodate the drive train being moved back and also a doubler box added to the existing drive train.

THe original grill will be used, I just like the look of it, as will the front fenders for the same reason. The motor is almost ready to come out.

This motor, a 22R will not be used in this project and will be sold. A 22RE which is fuel injected will be used in it's place.

 

[NCFJ]

I't all apart now! Lots of scrap metal to be hauled off to the scrap yard. The cab is now hanging on the trolly and out of the way. I'll be happy when I build a shed and clear the rest of the yard equiptment out of the shop.

Saved:
Complete cab
both axles
steering box
trans
T-case
heater and related controls
body to frame mounts (may reuse rather than fab new ones)
radiator
master cylinders for brakes and clutch

Selling:
Utility bed
R22 motor
scrap steel
stock seat
steering column
misc under hood components

Truck #2 is now in the shop and will also be stripped to the frame

 

[NCFJ]

Vertical storage for the moment ;D

Truck number two, let the tear down begin

 

[NCFJ]

I know, I've been slacking off.

Truck #2 stripped and out of here. Everything being used is in the shop, the rest is in the scap metal pile.

That's Max the shop dog. He came with the house, sorta. Old owner's brother lives next door and Max got left behind with him, only Max seems to prefer it over here. We'll probably end up with him, he makes 4 dogs.

 

[NCFJ]

Been making a bit of progress, there are a lot of projects going on in the shop and of course my own truggy comes last on the list.

Both trucks are completely stripped

All the scrap metal from the tear downs have been taken to the scrap metal man

motors and gear cases are seperated

the 89 rear axle that I am using in the truggy has the axles pulled and the spring perches and all tabes have been cut off and ground smooth (that particular job is all kinds of fun)

started on preliminary drawings of frame layout, cross members and motor and T-case mounts.

Gods willing and the creek don't rise, I should have the main frame steel and some of the tubing in the shop by end of next week!!!
Can't wait

Stan

 

[NCFJ]

SOmeone on another forum aksed about a general run down..........

I am good on engine parts at the moment. Currently have two 22R and one 22RE I do appriciate the offer though.

Overall game plan.............nah I dont want to publish that, I'd have to live up to it. I am just in tear down and clean up of the parts I plan to reuse.

But for now

I want to use the fuel injection so it is either the RE or a conversion for the R. The up side is that the conversion includes all new under hood wiring and computer. So I can run the fuel injection as a pure stand alone with no BS of taking apart the stock wiring harness and then trying to eliminate as many sensors as I can . The conversion is easier and less hassle down the road.

In either case the motor will be rebuilt top to bottom as will the trans,doubler and T-case. I really only want to do all this once putting in a tired old motor and questionable cases is just not worth the hassle. Drive line I am hoping to pull back about 8" in the frame, that is subject to change though.

Ground up frame, partial exo cage around the cab, interior caging. Enough platform in the back for fuel cell, tool box, recovery gear, maybe battery, maybe radiator...maybe

I am thinking 39s ,bigger brakes, hydro assist steering ( I am putting tags on it)
89 rear axle, 3" IFS hub swap to 82 front axle. Longfield axles in both, Lockers in both

That is far as my brain will let me go at this point. I have a direction on suspension but not quite there yet. I have enough to think about for a while.

Stan

 

[NCFJ]

I got some work done on the Truggy today. I was able to get both of the main frame sections built. They are 2X3X 3/16"wall rectangular tubing. Hoping to tack in a couple cross members tomorow or Monday.

 

[NCFJ]

I have been able to put a little time toward the truggy build. The front frame section is up at ride height, the axles are located and the motor is hanging in it’s intended position. The floor of the shop is straight flat and level. I painted a white building box on the floor. Center both ways, inside of frame, and axles are marked on the floor. I use a plumb bob to set everything.

I’ve been working on a 4 link calculator for the rear and 3 link for the front for a while now and getting the suspension design worked out. I’ll be stripping the motor this weekend and starting on a set of motor mounts.

Some Specs…….

Wheel base 114”
Front axle moved forward 3”
Moved motor back 11”
Moved motor Down 2.5”
Ground to bottom of frame 23”
Tires 39”
Front driveshaft aprox 42”
Rear driveshaft aprox. 42”
Target Travel up 4” down 10”

 

[NCFJ]

I finally found some time to work on my own project. I got both the motor sides of the motor mounts built.

 

[NCFJ]

I got the main supports on the frame side cut today. They will be boxed on the top and have angle braces back down to the frame as well. There is a reason for this particular design, any guesses as to what the reason is?

 

[NCFJ]

So many Toyotas, so little time

 

[NCFJ]

I got a lot of the T-case cross member done today. I am more interested in the frame mounted pieces over the cross member itself. It will rotate 180 degrees on the cross member to be installed, the T-case and trans will drop out from under the rig.

There will be bracing between the 2X3 and the plate and a bolt top to bottom in shown hole. 11.5 " between the mounts, 24" between the frames. The side plates held up with the magnets weld to the frame for extra support.

 

[NCFJ]

Started work on the rear axle. The rear of the axle is pretty thin and a skid plate is needed. The top of the skid plate will also help support the tower for the mounting points of the upper links.

 

[NCFJ]

Yes Virginia, there is a Santa Claus!!
And he delivers via Fed Ex.
Received the Marlin Crawler Dual Case Kit today. Let the games begin

 

[NCFJ]

I was able to get the doubler together and bolt the T-case up to it today. Tearing down the donor case took a while because two of the bolts were seized into the case. Nothing some heat could not handle, just time consuming.

The quality of Marlin Crawler equipment is well worth the money. I could have purchased a doubler from Trail Gear but I felt this is a true case of you get what you pay for and went with Marlin, no regrets at all on that front. Marlin invented it and has perfected it over the years including better bearing support and better oiling.

I am hoping to find some time tomorrow or Tues to bolt up the trans and install it all on the back of the motor.

 

[NCFJ]

I had a pretty productive afternoon in the shop today. Got the trans and cases bolted up to the motor and supported and sat the cab on the frame rails to get a feel for how things will line up.

I did some measuring and I think that I can lower the motor and drive train 2” in the frame rails and still have a flat belly pan and have enough to clear the upper link in the front end at full stuff.

I went with the rotated case doubler to make sure that the front drive shaft would clear the cross member supporting the T-Case, turned out to be just enough and keep the cross member above the bottom of the frame rails. Even a blind squirrel finds a nut once in a while.

A little time with the sawzall and the cab floor and firewall were gone. I’ll be building all new to replace it once the final position of motor and drive train position is finalized. Cross members and seat frames will carry the new flooring and firewall.

As the cab sits right now it is 6” from the bottom of the frame rails up to the bottom the of the seam on the rocker panels and 14” between the outside of the frame and the same seam. I plan to boat side this area. The cab still needs to move forward about 6” but the cowl is making contact with the top of the intake manifold. Once the motor is dropped in the frame this will no longer be an issue.

 

[NCFJ]

Dropped the cross member so the bottom is in the same plane as the bottom of the frame rails, It’ll hold two bolts for the belly pan. Urethane bushings and 9/16” bolts.

The driveshaft flange and U Joints are the determining factor here, on how much to remove from the plate and how close to the plate.

 

[NCFJ]

I was able to get all the cross member pieces fabbed up and welded today.

This section bolts to the transfer case, bolts through the urethane bushings to the cross member.

Installed and tacked into the frame rails