Builds BoltRipper's 2-year Overdue Build Thread (1 Viewer)

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9/21/13 - 84,000 Miles

Added Slee Accessory harness & Switch to wire in my Rigid SQ-2 Driving lights. The driving lights are activated with the high beams so I never forget they are on when I have oncoming traffic. I wanted something low profile as not to block air-flow into the radiator, but give me enough light for off-road night driving.

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LIFT TIME:bounce:

Finally it was time for the Lift. talked with Christo and Ben at Slee and decided on the 850 Front and 863 Rear Coils along with OME Caster Bushings and radflow 2.5" Shocks on all corners.

Removed the front coils and shocks:

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Replaced with OME Coils:

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Replaced the caster bushings:

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Next Came the Radflow Fronts:

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Then the Rear was completed:

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Shocks were next:

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Before:

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After:

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Ride and handling were great. No Driveline noise - Everything was perfect... Thanks Christo and Ben and the crew at Slee for their recommendation for Springs and Caster Correction....
 
Any chance i parked next to you at Starbucks in Montgomery a two or three months ago? It was early evening i was coming back from my uncles cabin. My truck was a dirty dark green 80, 33s, OME 2", bumper, winch, sliders and Gamiviti roof rack. Any chance that was you?
 
10/14/13 - 84,450 Miles

Replaced the drip moldings and all the window runs.. That sped up the windows considerably.

Added LC Phils Front Sway Bar Disconnects and a set of sway bar spacers to correct geometry from the lift.



1/17/14 - 86,560 Miles

Replaced and extended the front and rear axle differential breathers and added small fuel filters to keep water out.



1/30/14 - 86,950 Miles
Started receiving all the front axle parts from Onur and decided to tear into it.


Come to find out that the truck had 1 previous front axle service so that was good news. I didn't have any clicking, but decided to swap birf's since I was doing the service.

Here is what I started with:

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Getting closer:

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Not too bad a condition inside the knuckle:

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The messy job done for now:

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I replaced everything, bearing & Races, All Seals, Studs - Nothing was reused....

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Before tearing the Birf's apart:

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After a good cleaning:

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Keeping Everything separated:

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Replacing the Studs along with Cone Washers, Flat Washers and nuts.....

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1/30/14 - 86,950 Miles

Continuation of the Front Axle Service:


Driving in the new races:

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New races upper and lower along with the new axle seal:

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Yes - New Studs, Cone Washers, Flat Washers and Nuts as well...

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New Soft Lines and Calipers - All OEM...

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Starting to get things back together.....

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Repacking the Birf's....

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Repacking the knuckles....

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Yes - I repainted everything before reassembly... That will be a one and Done :)

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Inner Bearing and Seal...

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New Rotors, OEM of course and I'm ready to install...

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Outer Bearing Assembly...

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New Drive Flanges as well... Now I have spares.....

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So clean......

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Thanks for watching!!!!
 
1/31/14 - 87,000 Miles

Installed Nicks Depos and HID's

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Added some rubber backing to ballasts for vibration protection....

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Secured the ballasts ...
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Low Beams....

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High Beams....

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Next it was time to modify the ARB with the WIldYotes DRL's

Stock Bumper Before...

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Getting Ready for the cut...

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Cut and Drilled...

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Preparing the DRL for Installation...

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Exposed Metal Painted & Silicone added...

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Done...

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3/1/14 - 87,659 Miles

With the original radiator being a 1997 and having no issues with cooling, I decided to replace the Radiator with a New OEM rad as they were getting scarce. Id clean the old radiator and keep it as a spare.

Started by doing another complete flush of the cooling system and a complete drain.

The old rad was in good shape and would make a fine spare...

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Nothing like new OEM...

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Filled with 50% Amsoil Coolant and 50% Distilled H20


Replaced the fluid clutch with new OEM as it has cooled fine since 1997... No reason to mess with that... I did however upgrade to the 3FE Fan Blade and all new hardware.

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She roars now :smokin:
 
4/11/14 - 88,667

Time to PM the Fuel System.......

I had already replaced the fuel filter when I did the Baseline PM.... Since I was pulling the interior to start the sound deadening project I figured I'd replace the fuel pump.. Not needed, but as you've seen so far I started out to make a 100% reliable rig and that's what I planned to accomplish.


Pulled the cover plate off to access the pump...

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Pulled the old pump out and it was in great condition...

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Thanks to Onur I started to replace the parts...

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Fitted the new pump sock and other small bits...

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Also replaced the inlet Fuel Hard Line for good measure...

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Covered her up and she's good

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Whats Fuel without Air so I replaced the stock 97 Intake tube with new OEM as well and cleaned the MAF Sensor again....


I finally got lucky I guess... The Original Windshield was pitted and had a few small cracks... Since I was removing all the interior I figured it was time to replace the windshield as the headliner was down..

I was still contemplating spending the cash for new Japanese Glass when I took a Golf Ball to the front windshield while on the way home from work one evening... Luckily the kid admitted the errant slice and his dad cut me a check for new Ashai Glass.....

One quick Call to Onur and I had a beautiful new windshield and OEM gasket... Found an installer who would follow the FSM instructions and he installed it while I watched... Cassady and Self Glass Company in BHM if anyone is in need of a FSM Installed windshield. :cheers:
 
4/12/14 - 88,667 Miles

INTERIOR MODIFICATIONS:


As previously mentioned I decided to tear every bit of interior out and completely dynomat and dynaline the truck prior to completing the electrical part of the build.

Pulled the interior and headliner and started the process of removing the factory fluff sound deadening on the roof..


Before.... She was a very clean truck from the start.

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Headliner, Sunroof and interior removed.....

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Next Generation of Cruiser Head :princess:

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All Cleaned up and ready to start the Dynomat and Dynaliner...

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Here is a good shot of an empty 80 series.. The doors were last and also completely covered with dynomat and dynaliner.. I didn't get pictures as anyone who has done a project like this will attest that it just about killed me..

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Starting the Dynamat... Took twice as long as she had to Roll it after I put it up;)

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After the install of the Dynamat I did Dynaliner 1/4" on the roof as well. This would work to reduce the heat and I'm happy to report that the hard work was well worth the results.

I cant find the pics of the Roof, but this shows what the Dynaliner looks like on top the Dynamat....


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Wow. Jealous of that super clean rig and super clean workspace. Nicely done.
 
The Interior work continued into May and included the floor, Trans Tunnel, Sides, Doors and Tailgate all done with Dynomat and finished off with Dynaliner.

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I would estimate that I have well over 100 hours of labor into the the sound deadening project, but it was worth it. The truck sounds completely different now. From closing the door to driving in rain its very quiet.

Interior heat reduction was probably the best benefit. July and August are brutal and the Dynaliner along with Tinting all the Windows really helps keep the interior cool those days.
 
5/8/14 - 89,000 Miles

Interior work continues. I replaced the steering shaft seal while I have everything out.

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New Seal..

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Carpet was in great condition, but I rented a carpet cleaner, used Folex and made it look brand new...

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In preparation for the electrical project I installed Slee's Washer Relocation Kit and added a Diehard Marine Battery. The system would be controlled via a National Luna Dual Battery Controller.

Slee Kit...

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OEM Second Battery Tray Installed...

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National Luna Kit, Ready for Install...

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The Solenoid was mounted on the rear of the second battery tray...

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Starting the wiring to the primary Battery...

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The National Luna Kit is great. Highly recommended and Paul from Equip1 was a pleasure to work with on the purchase...
 
On 6/14/14 the truck had its 1-Year Anniversary and turned 90,000 miles.

I've completed a ton of work to a perfectly good and capable truck. At this point I've reached that wonderful Mud Initiation point of having more cash in the mods and build than I paid for the truck. Fortunately or Unfortunately I'm a project guy and this is my therapy. I enjoy every minute working and ended up selling my other truck, a 2013 Jeep Rubicon that was also a project truck to which I completed a Chevy LS3 Conversion with a 6L80E transmission.

The 80 had a soul and that was something missing in everything else I had driven. I was always a new car/truck guy, but the Toyota changed me. Jeep, BMW, Mercedes, Chevy, Ford I guess I had tried most... Just couldn't stay out of the Toyota.....


At this point I started one of the biggest projects, the interior electrical. I was looking for power distribution to an inverter, 12V Sub Panel to run my ARB Fridge, plenty of USB outlets for me and the kids along with 120V power in the front and rear of the truck.

Lets get started....


First I needed to bring power into the truck so I started by making a bracket to hold a Mega Fuse. I also wanted an emergency cutoff. While not a popular place I decided to place it in the engine compartment.



Starting to make my Mega Fuse Bracket...

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A few more bends and....

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Finally...

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All complete with mounting holes....

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Mounted and Painted to Match the Exterior with Clear Coat.

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Emergency Cutoff Location...

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So here is where I brought the Garden Hoses of a power and ground wire into the interior of the truck....

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Next I needed a place to mount the power Distribution supplies and 12V Blue Sea Panel... Started fabrication of another bracket for that setup..

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At this point Im really enjoying the 20T press and sheet metal brake....

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