Builds 86 Xtra Cab Build (4Wheelunderground 3 link front, 4 link rear and 3.4 swap) (8 Viewers)

[aztoyman]

I got the top plate made, clamped down and welded up. The inside edge is just tacked up. The monsoon got me again so tomorrow hopefully I can finish it.

If I can get my neighbors to help, I'd like to get the cab out in the driveway to pressure wash it. While it's out there, I'm going to flip the frame over and weld the rest and make the bottom plate.

Still trying to decide what to do about the corner at the front crossmember. Thinking I may use my steering box mount to tie in? I guess I'll cross that bridge when I get there.

 

[aztoyman]

I got the cab out today and pressure washed it. Unfortunately I found a hole in the floor behind the driver seat thanks to packrat pee. A friend of mine is cutting a section of floor from another truck that caught fire. Hopefully I can make a patch.

 

[aztoyman]

I also found out why the core support mount and front crossmember was a little tweeked. Looks like maybe the front clip was swapped or repaired. I found some new welds where the factory spot welds should be. Not really an issue for me with all the mods I'm doing. The hood and fenders lined up fine.

 

[aztoyman]

I also got the frame flipped over. My overhead welds didn't look too bad.

I finished welding the bottom, did a little cleanup grinding and starting fitting the bottom plate.

 

[aztoyman]

I really need to finish the welding tomorrow. I kind of hid the cab in front of our vehicles. The HOA will get me.

I can at least set the cab back on the frame INSIDE the garage.

 

[Broski]

Looks like a nice build, I well be following a long.
I wheel with a group of Toyota guys. were not a club.
One of the guys has a first Gen 4runner with 4WU suspension front and rear. It's the most capable Reg in the group. I think you will be super with the 4WU three link set up.
Keep the piks and posts coming.
And welcome to mud the official salute.

 

[aztoyman]

Thanks Broski, I'm excited about this build. My neighbors with Jeeps invited me to join their club. I usually just wheeled local trails. The club is nice because they go out of state. Moab, Sand Hollow, Rubicon. It's nice to be able to go with people familiar with the trails and areas.

Here's another try with a pic that didn't make it. The hole in the floor.

 

[clx16]

Seeing what you are repairing makes me feel much better about the work I need to do on mine. I just need to overcome lazy...

 

[Broski]

Thanks Broski, I'm excited about this build. My neighbors with Jeeps invited me to join their club. I usually just wheeled local trails. The club is nice because they go out of state. Moab, Sand Hollow, Rubicon. It's nice to be able to go with people familiar with the trails and areas.

Here's another try with a pic that didn't make it. The hole in the floor.

View attachment 2721337

Haha we go to the same places, just got back from the Rubicon. We also like Johnson Vally ( the hammers )
I hear there are good trails in Arizona ?

 

[aztoyman]

I couldn't make the trips to Cali....Yet.

AZ has some baddass trails. Some very scenic and some will tear you up. I've mainly wheeled around Tucson and Florence areas. Phoenix has some good stuff too.

My 88 is ready to go. The whole state seems to be on fire right now. Much of it is closed to camping, shooting and off roading so now is the time for me to make some progress on this 86.

CLX, I'm retired and one of those guys that can't sit still. I'm in rough shape physically and on a fixed income so I work slow and steady. I'm doing this with cash only so that's my biggest obstacle. I have credit cards but, I don't want to have a monthly bill to pay. I'm sure something will inspire you to get back on your project.

 

[aztoyman]

I got the bottom plate made, clamped down and most of it welded up. Didn't get it finished since it's the 4th of July. Cookout and swimming with the grandkids took priority.

 

[aztoyman]

It was a HOT and HUMID day to be out in the garage welding. Got it done though.

I guess my next task will be cutting brackets off the front axle housing. At least I'll be ready for the 3 link parts.

 

[aztoyman]

I got the 85 axle housing brackets all cut off and ground smooth. Got a couple nicks from the plasma cutter I need to weld. I need to reinforce the steering stops too.

Cutting off brackets and grinding is my LEAST favorite part of doing a SAS. It's gotta be done though.

I may as well do the rear axle housing while I'm on a roll. Maybe tomorrow. RuffStuff had a 4th of July sale so I ordered their rear back truss.

 

[aztoyman]

I didn't get to the rear axle housing yesterday. Had a family matter to take care of.

I decided to make some progress on the cab today instead. I need to get the sound deadener out for two reasons. So I can weld the damaged areas and I'm thinking of using bed liner on the floor instead of carpet.

It chipped out of my 88 easily. Not the case with this truck. It's still pliable and difficult to remove. Probably because it's over 100 degrees in my garage. Someone on another forum said to chill it with dry ice. I tried a couple gel ice packs we had in the freezer. It worked. Chilled it and chipped it out. This is ALMOST as fun as cutting and grinding IFS brackets.

Here's some pics. I have some repairs to do. Hopefully my buddy comes through with the section of floor he offered.

 

[aztoyman]

Finally finished chipping the sound deadener out of the cab. I found a better way to do it. I modified one of my air chisels so it wouldn't cut or punch a hole through the floor. It got underneath and easily peeled it off the floor. It seems as if the vibration breaks the bond over a large area. I was able to peel off large sections. The only areas that didn't come off were over seam sealer. Quite the bond and gummy.

I'll start on the welding once I get the piece of floor my buddy is giving me. I'll switch my welder to .023 wire.

 

[aztoyman]

I guess my next task is to cut brackets off the rear axle housing and start the bed bobbing process.

 

[aztoyman]

Got back on it today. Got the steering stops reinforced. I forgot to order RuffStuff's solid steering stops when I ordered the back truss so today I improvised.

I had heard that 5/8 nuts were a good fit inside the factory stops. I didn't have any but, I did have some OEM Toyota nuts in my stash that fit perfect.

Before welding them in, I traced the shape of the stops on some scrap flat bar. I cut them out pretty quick with my 4 1/2" grinder with a thin cutoff wheel.

Welded everything in and it's good to go.

 

[aztoyman]

I at least started on the rear axle housing. Got the brackets and spring perches cut off. I still need to finish grinding some of it flush.

 

[aztoyman]

Well today I cut a foot out of the bed. Before anybody gets upset about chopping up a vintage Toyota bed take a look at it. It's rough. I wouldn't have cut it if it was in good shape.

This is the first one for me. I found a lot of pics but, not much for detailed instructions. I spent more time just trying to find a place to cut and finding reference points to measure from. This bed is..... tweeked.

The inner panels are really bent as were the brackets they bolt to. There's a big dent in the floor and check out the rear valance panel. The tailgate is beat as well.

Here's some pics. Hopefully I can make it work. Might still be going flat bed if not. I'd like it to still look like a Toyota pickup as much as possible.

 

[aztoyman]

At least the bed sides are pretty straight. Gotta weld'r up yet. Might be trimming wheel openings once I see how the suspension flexes. If I 4 link it I'll need a fuel tank.