Builds 1HNDRD build (1 Viewer)

[skyblue]

I figure it's time for an update here...

Unfortunately, I haven't been able to get much accomplished on the build lately for various reasons. However, I did have some time today to get a few little things done.

In the meantime, I've been ordering and receiving wire, connectors, relays, and all kinds of related items. Ordering this stuff has forced me to attempt to educate myself on what is needed and how it goes together. I'm nowhere close to being an expert but I do feel like I've gained enough understanding to accomplish the goal. Also, I'm certain that I won't do everything the best way and I may even do some unnecessary stuff as well...

Anyhoo, here is what I've been up to..

I'm building in a 12-circuit fuse panel, 10 relays, and a couple of terminal strips to keep it all tidy and edit-able. This many circuits may be way overkill but I think it will accomplish two things. One: I can add future switches/accessories quite easily, and and Two: all the fuses and relays for future front-end stuff will be in one location.

Last week, my first attempt at a fuse/relay panel ended up being too small...

I was really pleased with the fit and finish but when I started to understand everything that needed to attach to it, I decided to start over with a redesign. I ordered a larger piece of ABS plastic and an additional terminal strip and went back to the drawing board...

Here is what I've got so far..

A cardboard template. I can transfer this to the plastic as soon as it arrives.

All-thread supports cut to length and installed. (see support locations in the template)

I will need to add length to 2 of the wires coming out of the relays so they can reach the terminal strips. I'll likely route these wires beneath the panel to keep it cleaner. Plenty of space underneath. The terminal strips will be conveniently located near the firewall where the switch legs and roof rack lights come thru..

So since I was waiting for the replacement supplies, I moved on to step one of the dual battery system...

 

[skyblue]

I needed a place to mount the "Intelligent Solenoid"
Luckily I had a wasted piece of ABS plastic ...
From what I can tell in the pictures on Slee's website, I should still have room for the future air compressor..

Hopefully, once I receive some of the last few items I've ordered, I'll have everything I need to make some real progress on this...

 

[skyblue]

Another shout out to @RocketCityCrzrs for answering all my elementary questions and helping me understand the electrical a little better...

 

[RocketCityCrzrs]

Always happy to lend a hand and can't wait to see this truck completed

 

[skyblue]

Meanwhile...

 

[molonlabemike]

Solid work! If I may ask, what thickness are the spacers?

 

[skyblue]

Thanks!
They are 1.5"

 

[molonlabemike]

Awesome! Gonna order a set

 

[skyblue]

Be prepared to wait...

 

[molonlabemike]

Be prepared to wait...

yeah I was reading that and boy they are stupid $$$.

 

[skyblue]

Firewall boot installed this evening. Was nervous about drilling in the wrong spot because it appeared to be 2 layers and I wasn't sure what was in between. I carefully measured cab side/engine side using the factory harness as a reference and it turned out to be a single layer. All good.. If I was doing it over I'd go as close as possible to the bolt that you can see on the inside (but for some reason it doesn't come thru from the engine bay)

On another subject... I had the exterior detailed yesterday. Mainly because there was lines from the fender flares that I removed. I was confident the lines would come out without a problem.. Unfortunately, they did not. It's better than it was but I'm gonna have to live with it I guess.

Been driving it daily the last while. It's a pleasure..
However, I am looking forward to getting the bumpers installed for some extra weight. The springs are a bit rough without the weight they were designed for.
If I can ever wrap up the electrical phase... I'll be ready to move on to something else.. Doing my best to move at the speed of right

 

[neilsen100]

Firewall boot installed this evening. Was nervous about drilling in the wrong spot because it appeared to be 2 layers and I wasn't sure what was in between. I carefully measured cab side/engine side using the factory harness as a reference and it turned out to be a single layer. All good.. If I was doing it over I'd go as close as possible to the bolt that you can see on the inside (but for some reason it doesn't come thru from the engine bay)

It looks like you installed the boot the incorrect direction. It is designed so the nipple points into the engine bay. In the unlikely event water reaches the boot that far back into the engine bay, it would enter the boot leaving sitting water inside the boot and possibly leak into the cab. Don't know if this practically matters in the real world.

 

[skyblue]

Thanks!
I will turn it around...

 

[skyblue]

Thanks @neilsen100...!
I do like this better

 

[savirc]

Thanks @neilsen100...!
I do like this better

View attachment 2324011

Yeah the boot was backwards, on a side note looks like changing brake fluid out should be part of your list

 

[skyblue]

Decent day on the project today...
After doing a little repair on the 40, I installed the light bar on the rack. I haven't wired it up yet (still working on electrical) but I needed to get it installed to make the rack quieter while driving. This particular dual function light bar is a bit wider than a standard 40" so it requires a bit of notching on the cowling...

Looking forward to getting it hooked up!

Next I decided to start some rough assembly of a couple of wiring harnesses. First I tackled the one that connects the auxiliary battery and the main battery and feeds the fuse/relay panel.

 

[skyblue]

Here it is kind of installed ready to tie in the connections... Still need to add the 100A fuses to the main + leads

Also I upgraded/cleaned up the ground cable and post connection on the main battery..

 

[skyblue]

And then went ahead and did sort of a preliminary assembly of the main rack lights harness. It also includes a 10ga pair to run to the rear of the truck to power the fridge. (previous owner already ran power to the rear but I wanted to take it from the auxiliary battery so I'm re-doing it)

Last thing I completed the easiest part of the whole electrical phase... Switch panel assembly. (took all of 90 seconds)

Next week I'll try to finish up the fuse/relay panel. Hopefully the AGM battery that I ordered will arrive and maybe I can wrap up that part as well.

 

[Mike Beauford]

Just a quick comment. My local Rockwall Texas Toyota dealership. They offered me a one time price for a lifetime front end alignment service at their dealership. So I can play and get an alignment and change my mind and get an alignment... So this weekend I am correcting a big mistake on my part. I am 2 years into my 2005 100 Series build. When I bought it, it needed a lot of front suspension work. I (BIG MISTAKE) cheaped out and bought Mevotech Upper and Lower Control Arms and inner and outer tie rods and paid to have a local shop install them. The bushings were crap and after 20K and 16 months of light highway use (no bushbashing), the lower control arms bushings are done. So I ordered OEM Lower Control Arms and outer tie rods and boots. They were installed this weekend and I will get the "free alignment" done today. So my tip is see if your local dealerships offer the lifetime alignment. Use it twice and it more than pays for itself.

 

[abuck99]

Enjoying following your project. My kingdom for your barn/workshop space!

Next up- two post lift?