Builds 40 Guy Builds a 100 Series

[REZARF]

I also had a little time to work on my winch. I ended up training my m12000 for a Warn xd9000 and enough cash to buy a synthetic rope. I bought my rope from Custom Splice in the 3/8" x 100' in grey color. I also had enough scratch left over for a Slee aluminum haws fairlead.

I pulled the ARB bar off to mount up the winch with grade 8 bolts and unspooled the wire cable. Man on man, that old cable bird nested on me big time!

Pretty awesome approach angle sans bumper. I measured how far Warn painted the cable red so you know when to stop free spooling the winch and leave enough wraps on the drum for safety. I decided to use that concept on my synthetic rope.

The Warn control solenoid box fits like a glove into the opening on the Sahara bar but leaves you no room to mess with it inside if you need to trouble shoot anything. I double checked all the wiring was correct and snug and bolted it down.

I went ahead and added about 7' of tubular webbing to the eyelet end of the winch rope. This will serve the same purpose as the painted cable and give a visual clue as to when to stop spooling out rope. I like that I can see it from the end of a 100' pull of the rope if I am working solo in a recovery.

 

[REZARF]

Gearing up for our camping season here in Colorado. As soon as the snow melts in the high country we are off and about all summer before the white stuff comes back. I took some time to go through my gear and pulled out an old favorite my Kelty Carport. In lieu of a retractable awning I can set this guy up in about 10 minutes solo or 15 with someones help

It can snug down creating an open floor tent with access to the rear door, erected on either side or rear depending on what we are hoping to gain. It has windows on three sides that can be rolled up for screens or down for a little more weather protection or changing privacy. It also comes with 2 poles that can be used as legs to raise the far end and create a large open area for eating, chilling or quick shade.

I love this thing...

 

[REZARF]

Next up, I started working on rear lighting for camping, negotiating off road trails and rear illumination at Costco I wanted a removable non-permanent solution to adding a few rear facing LED lights that I can move to a roof rack down the line. Here is what I started with:

Hella has a line of LED lights called OPTILUX, this is their Mini Light Bar 6, it is small and super bright, I chose a pure flood light for this application as I wanted to spread out as much light as possible. I am impressed with these lights so far, they are well made, waterproof and seem rugged. Simple two wire hook up, more on that later.

Engraved logo.

Here is the self made kit I used to install these guys where I wanted them to go.

 

[REZARF]

So to make these non permanent I decided to mount them right under the rear spoiler thing (anyone know what this thing actually does? I am assuming it keeps mist off the rear window). To mount the lights off the spoiler mounting bracket I needed to fab some simple spacers. I grabbed a block of ABS from the scrap bin in my garage and began to measure and cut them to fit.

This is where they will mount up, this is the mount of the spoiler at the very top of the rear hatch. There are few bolts that hold the spoiler on that are captured in this mount, so I am going to tap into the rear-most threaded hole to mount the lights onto.

After a little measuring and fitting the lights I drilled the hole in the right spot.

This is how the mount will space the light off the bracket. It is simple but effective.

 

[REZARF]

The finished result is clean and simple, again these are to get me through the season until I can fab a roof rack or Prinsu comes online for the 100 series, or I cave and pick up one of the awesome Gamviti racks.

One done, one to go.

Knocked them both out. I have decided I am going to power them two different ways. I am going to run a diode off my reverse lights and allow them to illuminate every time the reverse lights are, as well as, a switch in the cab to turn them on when I want them.

Sorry the truck was filthy but I had the time so I went for it. I'll try to post a few off/on pics if I can figure out how to do it with my camera.

 

[REZARF]

My 3 year old helper approves!

 

[TheForger]

Well that is the coolest tent/canopy, I've never seen one of those but might have to pick one up! When you do the wiring for the lights do you mind explaining and/or drawing a schematic of how you wired it? I want to do something similar with my rear lights. Sweet rig!!

 

[REZARF]

Well that is the coolest tent/canopy, I've never seen one of those but might have to pick one up! When you do the wiring for the lights do you mind explaining and/or drawing a schematic of how you wired it? I want to do something similar with my rear lights. Sweet rig!!

Sure the wiring is as simple as adding a 5 amp diode off the rear reverse light power lead to the (+) power on the light. For the switch you run + power wire from the switch to the positive of the light.

 

[KyTrkyHntr]

I'm getting my 100 back from the Wifey and this thread is awesome!

Thanks!

 

[REZARF]

Slee rear bumper with tire carrier on,
Battery in,
Readjusted the TB to level from the droop after installing the Slee bumper/Tire carrier,
Winch installed,
Realignment on the front end
Hi lift installed
Road shower installed
Thule box painted and installed
Trasharoo installed
Sheep skin seat covers installed (temporary borrowed from a friend to test drive them).
Rear brakes installed.
New igniter coil on #5 cylinder
Fridge hardwired

Whew, been a hectic few weeks but we are ready to camp and wheel!

Pics to come!

 

[REZARF]

Spent a week with the family at 2 of our national parks here in Colorado... The Great Sand Dunes and Mesa Verde. We even got into a little dirt and my wife took the wheel with our three kids 5, 4, 3 cheering her on. I simply love the 100 for family trips its so comfortable and drives long distances with ease.

 

[10ga]

Love your rig. I bought mine already built but going through your build thread gave me some ideas of stuff I need for mine.

 

[DJCloz]

So I tore into my engine to get at the starter contacts. I went by the local auto parts store to have them test the battery and alternator just to make sure and everything came out peachy there, so I knew it was the starter. Well, it took me an afternoon into the evening with some breaks and dinner, and reading in the manual but alas I got down to the starter and replaced both sides of the contacts and the plunger with OEM parts from Toyota.

If you didn't know the starter is conveniently located under half of the engine Robbie of Toyota Trails Tech Guru Extraordinaire happens to be a friend and local mechanic to me. He said that the starter is located there to avoid the heat soak factor of the factory exhaust system, he talked about it being smart and that it helps the longevity of the starter itself... that may be, but it sucks to get to it.

You only need to unplug, unbolt, unclip everything that attaches above the cylinder heads. All in all it wasn't hard, just time consuming. View attachment 1257814
It was a welcome sight to actually see the starter.
View attachment 1257815
Here is a shot of how dusty and worn my contacts were. The unit smelled like burnt electronics... yummmmm. I cleaned it up, checked all the wires and started replacing parts.
View attachment 1257816
I think the plunger and both contacts sets were only around $30ish bucks from my local Mr. T parts dealer. I could be off but I don't have the receipt handy. I am glad I replaced the plunger too as mine was very worn.
View attachment 1257817
Out with the old, in with the new. These are about 1/2" on each side... this is the culprit if your 100 begins to start intermittently. The new one is on the right
View attachment 1257818

What kind of signs did you have to show you that your starter was failing or did it just fail out right? My truck doesn't seem to start up as fast as it used to, but I may be splitting seconds. Its also not that bad.

 

[REZARF]

What kind of signs did you have to show you that your starter was failing or did it just fail out right? My truck doesn't seem to start up as fast as it used to, but I may be splitting seconds. Its also not that bad.

I was having the solenoid click but not having the motor turn over. After 2-10 "clicks" it would fire.

 

[REZARF]

Before our National Parks Trip I decided to get after the rear bumper tire carrier and bolt it up. Christo and the gang make an outstanding product and I got this one since it was welded up "wrong" and was told it wouldn't bolt up without modification. Once I got down to it I measured about a kerbillion times and couldn't see anywhere where it wouldn't bolt up. So, I enlisted another Cruiser head and went for it. It bolted up without issue accept for a widening gap at the top edge of the wings in relation to the rear quarter trim. My wife calls it my "discount gap"

Installation was easy. Unbolt the hitch, the bumper cover, and the steel bumper substructure and you have a clean slate to bolt to. Before:

The rear bumper cross member and chassis were in fantastic condition. I pressure washed everything underneath and considered a fresh coat of paint but in the end it simply wasn't necessary. The PO had taken good care of this cruiser and it was garage kept. I was blown away how clean everything was.

This was our first trial mock up and the gap was HUGE, after adjusting a few things and maxing out the adjustment in the up position we closed this gap significantly. It still bugs me but I knew going into it I wouldn't be a perfect fit, so I can't complain too much!

Once we got it all dialed in and bolted up, the gap closed considerably. This tire carrier is really well built. It operates so smoothly and adds a ton of protection to the rear and rear quarters. I am finding I already miss the access to the rear cargo area, there is a lot of stuff to unlatch, release and swing out just to pop the rear hatch anymore. I can't imagine I would like a dual swing out for that reason alone.

I am planning a few mods for the tire carrier swing arm and bumper:

• I already added a 3/16" thick rubber pad under the hi-lift to
• I am going to add a gas strut to aid in opening the swing arm similar to BIOR.
• I am adding some LED license plate bolts to illuminate the rear plate.
• I am adding a backup camera to the center of the rear spare center cap.
• I will likely add recessed LED flood lights into the rear and side wings of the main bumper.
• I am adding a CB hard mounted antenna.
• I will add a 6# propane tank, either underneath in the spare area or on the swing out itself for cooking.
• I am searching for a rubber/traction pad for the main "step" of the bumper. I used it a lot for loading the roof top box and it is super slick when your shoes or the bumper is wet.
• I am coming up empty trying to find a dust cap for the spindle, I need a dust cap that fits the 2.45" ID opening.

 

[TheForger]

Looks great and what a deal on the bumper! Just my $0.02 - I would not put a propane tank underneath the truck. That just seems like a disaster waiting to happen and considering you most likely wouldn't have anything protecting it, there's a risk you could puncture it off road. Great job on the install!

 

[dubitup]

Looking good Drew! Pic of the battery set up or are you not done yet?

 

[ihadmail]

I am finding I already miss the access to the rear cargo area, there is a lot of stuff to unlatch, release and swing out just to pop the rear hatch anymore. I can't imagine I would like a dual swing out for that reason alone.

Time for a set of Emu Wing rear quarter replacements?

 

[REZARF]

Looks great and what a deal on the bumper! Just my $0.02 - I would not put a propane tank underneath the truck. That just seems like a disaster waiting to happen and considering you most likely wouldn't have anything protecting it, there's a risk you could puncture it off road. Great job on the install!

Thanks for the suggestion, actually I wouldn't install one underneath without creating a substantial skid plate. And with the spare removed, the cavity left by the spare is one of the most protected area's left on the cruiser surrounded by frame and cross members. I am thinking if I go that route to add one like a VW Camper Bus does them.

Looking good Drew! Pic of the battery set up or are you not done yet?

I haven't even started yet Alex, I have determined I can get both batteries in the right spot without major surgery under the hood to any sheet metal so I am moving forward. I need to fab a tray first and hold down first, then I can start the wiring. I plan on making my own wiring bus for the positive on the aux batter setup too. It'll take a while to knock it all out.

Time for a set of Emu Wing rear quarter replacements?
View attachment 1276526

Wow, I didn't even know those existed, very cool product but man at $1600/pair AUS that is a boat load more than I paid for the Slee bumper. Cool product but I'd have to really want them or be headed out around the globe to consider them at that buy in price.

 

[planomateo]

Wow, I didn't even know those existed, searching now.

Pretty slick.

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