Builds BUILD THREAD FOR THE "German Shepherd"

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Right after or before the Wyoming trip, I converted the AC to R134, added FZJ front brakes with slotted Stop tech Rotors and 100 Series pads. Along with those bigger updates, I changed the fuel pump filter sock, fuel pump gasket, and all of the heater hoses as one started seeping a little bit of antifreeze up in Jackson Hole. Other than that, I did not do much to or with the cruiser once school had started. Last fall I took advantage of the "Buy an ARB Fridge, get two free camp chairs" sale by purchasing a 60L fridge in preparation for the drawers I was planning to build along with a fridge slide.

I then had some issues with the power steering pump blowing out on the way back from Arkansas, which I then rebuilt and then decided to replace after something still didn't seem quite perfect. I also replaced the brake booster again as it was under warranty and still not quite providing the power I expected it to especially as the pedal was pushed down. Shortly after that power steering episode, we tore into the transfer case and replaced the rear output bearing and seal. I also rebuilt the driver's side front axle as it had gotten a little soupy. Once the larger repairs were out of the way, I set my sights on refining and replacing little things like the shifter bushings and grommets as well as the rubber shift boot that goes below that entire place. I also put in a new firewall seal around the steering shaft.

In order to have space for my drawers, I had to relocate my air tank under the vehicle and out of the old storage box that I had built to fit behind the 3rd row.

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I could then turn my attention to designing the drawers. I definitely wanted to have lock in/ lock out slides with two main drawers and space for a fridge on top. I ended up going with the 9301 and 9308 Accurides in 36" length for the two drawers and a 22" slide for the fridge slide.

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While working on the drawers occasionally between classes, I also went out to the Arbuckle Off Road Park with a buddy and his Trail premium 4Runner. Unfortunately, they just closed last month but I am glad I got a chance to check it out.

Despite being somewhat small, the place reminded me of Moab and the granite provided tons of grip.



Several weeks later and after a quick trip out to the Palo Duro to get some mountain biking in, I headed back out to Utah/Colorado for Spring Break. The trip was similar to last year's in terms of area, but Moab could easily be entertaining for months...as long as it isn't 100* outside. Lots of biking and some wheeling. We started driving around on random roads our first afternoon there and stumbled into Deadman Canyon if I remember correctly.

We started Poison Spider late in the day and didn't realize how long of a trail it was, but after the waterfalls, we turned around as it was starting to get dark.

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Upon returning home, it was apparent the cruiser needed a tuneup.


The idle was no longer really smooth and a slight miss had started occurring. A fresh distributor cap, rotor, NGK Iridium spark plugs, valve cover gasket, and valve adjustment really made a difference. It idles so smooth you may think it isn't running if it weren't for the sounds. That really amazes me after 400k miles.

Around this same time I had gone out to Arkansas for a quick mountain biking trip where I ended up taking a soil sample on April 1st. Three breaks in the jaw, a nondislocated orbital fracture, a badly broken wrist, a helicopter ride and two surgeries later I found myself crippled on the couch for what felt like an eternity as my jaws were wired shut. It wasn't until about July that I was finally able to eat lightly fried chicken.

Once I was able to drive again, my dad and I started looking into the vibration at highway speeds and found the upper and lower RCA bushings in bad shape. Here is the thread on that stuff

To eliminate any doubts, OME Sport Series L shocks were put on in the rear to help combat the vibration as the passenger rear wheel was noticibly vibrating around at highway speeds pre bushing change. The rear shocks ended up tightening up the ride and reducing body roll so a matching front set of shocks also went on. Just today I finally found out what was causing the body and steering wheel vibration. Here is the thread on what was replaced and adjusted while trying to reduce the vibration. Ironically, it up being fixed by going back to square one and ditching the balancing BBs in the tires for balancing weights.

I am sure I am missing some smaller things I did, but the thread on ExPo has been kept up to date in much more depth.
 
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Very nice update! My '92 is just getting broken in at 238k.

I wish I could set aside the time to make trips like this. Mine happen about once every 2 years.
 
Very nice update! My '92 is just getting broken in at 238k.

I wish I could set aside the time to make trips like this. Mine happen about once every 2 years.

Haha just barely starting the break in process. Lately it seems like mine has finally reached "broken in". A lot of little things have been needing to be replaced that most people never touch or think about. Shifter bushings and grommets and putting a self tapping screw through the steering wheel mount to fix a slight wiggle to name a few.

Might have missed it in the thread but what type of bike rack are you using?

It's a Northshore NSR4. Great rack, but if I were to get another I would be highly considering a Recon Rack. They hold all styles of bikes vertically without contacting anything more than a tire whereas the Northshore has rubbed paint off on my fork crown, and only holds mtb bikes.
 
Myself and four friends just got back from a trip up to Colorado a couple of days ago. After a bad mountain bike wreck last spring, I didn't think I would be making it out this year, but pushing through PT has really worked wonders. Anyways, I finished up my drawers and fridge slide just hours before hitting the road for Buena Vista and meeting up with a friend and has 100 series for Tin Cup Pass. He then joined us for rest of the trip in his trail edition 4runner. We started the trail at 10:30pm and set up camp on the summit in high winds and sleet. I ended up driving all over Colorado and went from Crested Butte down to the San Juans and then back up to Boulder. Definitely some awesome and memorable times for sure, and the cruiser performed almost flawlessly the entire time except for a strange headlight issue and super leaky power steering box. With 400k hard miles, I am sure that it is probably time for a fresh rebuild on it. Oh and also one of my rear air bags went flat...Now onto the cleaning and repairs.

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And here is the moment it rolled 400,000 miles ~30 miles from Salina, Kansas. It was pretty cool rolling 400k miles in a small convoy of three cruisers. We ran into @Juan Munoz on I-70 outside of Denver.
 
Finally about done cleaning. I spent several hours yesterday power washing the underside, followed up by some time at the car wash this morning and detailing afterwards just to get hit with multiple rounds of rain. Now that I look at the picture of these jacks I probably should have done it a bit differently.
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Since finishing a batch of swing outs and starting the semester, I've had time to rebuild the power steering box, which involved some extra down time after tearing the white teflon ring when reassembling it the first time. From there I went onto reworking the cargo shelf.

The rear cargo shelf has always been held on by a bunch of zipties and had a slight wiggle to it. I wanted to fix that and make it as solid as it could so it did not produce any squeaks. I cut out and bent up some new mounts and bolted it in. It's now awesomely solid and I can actually pull my weight on it and slide into the back on top of the drawers.

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About a month ago I went out to camp and explore some trails in the Ouachita National Forest with some friends. After a couple days which led us from Tallihina, OK to Mena, AR and then onto Mt. Ida, I was getting fairly bored of the rather tame trails. I saw a road sign saying Hot Springs was only 40 miles away and I knew they had an off road park. I went online to look up prices and low and behold the Southern Cruiser Crawl was going on so I persuaded everyone in the group to go there. Unfortunately we had to head back to Oklahoma that Saturday afternoon so we were only able to stay for several hours. The cruiser started behaving oddly whenever it was started up. It kept wanting to die and backfire until I got the rpms up to roughly 2000 at which point it settled down and performed fine. I don't know what was causing it, but I haven't been able to replicate it in the past month. While at the park I cleaned out the air filter and checked for any vacuum leaks to no avail.

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Other than cleaning and buffing the cruiser after that trip, I've briefly messed around with mounting the hi lift on the rear tire swing out. I've always had it on the bumper since that was really the only place I could mount it, but I got sick of seeing it there one day and pulled it off which really shows off more of the 80 series hood lines which I like so it will be relocated soon.

I've also got an itch to build a higher clearance front bumper...no idea when I'll find time to do that, but it's something I'd definitely like to do as I have a bunch of ideas floating around in my head.

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I still need to buff and wax all of the beige but I've been putting that off for when I take the flares off for a fresh coat of bed liner...which has been my plan for the past couple years now but I just never seem to have time to do that.

Tonight I set to cutting up some drawer liners out of some diamond plate fatigue mat I found at Home Depot. Makes them look much nicer. I'm going to put a diamond plate rubber mat on the top of the drawers to clean up the look there and offer a little more comfort when I'm sleeping in there.

I also need to put some sort of edge protectors on the top of the drawer edges. They seem to be getting chopped up quicker than I can sharpie over them.
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I've pretty much decided that sleeping in the cruiser is awesome unless it's raining and I can't have the windows down for air so I'll only be using the RTT now on trips with more than 2 people.

I also have plans to rebuild my receiver hitch. The anti rattle hitch pin stripped out this summer, and 4 bikes and a Northshore bouncing around absolutely wrecked my receiver set up. It's now really warped outwards and it popped some welds on the crossmember along with started extruding some of the nuts that back up the bolts through the cross member.

The 1/4" angle iron used to be mostly under the overhang of the crossmember step. I'm going to rebuild it with 1/2" and also do something different with how it ties in underneath.

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Within the next year I am hoping to upgrade to a set of locking axles or at least a full floating rear with harrop e locker.

I've also been lusting over the Autocraft Slinky suspension. I drive the cruiser pretty much every day, and the suspension now is beating me up and blows through the travel off road. My delimma is between the price of stage 1 and 4. Stage 2, while expensive is a lot less than stage 4, but I would end up wanting and going with the stage 4 down the road. That makes me think stage 1 would be a waste of money in a way that I would end up spending more money in the long run. Hard to justify it, but knowing I have no plans to ever get rid of the cruiser seems to make sense. Why not have the best suspension for it?

I don't think anyone here in Oklahoma had a stage 4 Slinky set up, but if someone does and you're reading this I'd love to check it out. I've ridden in 4runners and tacomas with "premium" suspensions, but that's IFS
 
Curious, did you find a solution for the hi-lift on your swing-out? I've been tossing around the same idea... since for the time being it's bouncing around in my trunk. I've looked at several different options...but nothing so far has been exceptional.
 
I still need to buff and wax all of the beige but I've been putting that off for when I take the flares off for a fresh coat of bed liner...which has been my plan for the past couple years now but I just never seem to have time to do that.
What did you use on the black trim pieces? It looks good.
 
Curious, did you find a solution for the hi-lift on your swing-out? I've been tossing around the same idea... since for the time being it's bouncing around in my trunk. I've looked at several different options...but nothing so far has been exceptional.

All I have done is figure out how much further to space my tire and cut the plate that the hi lift will set on. I still have to cut up my swing out to finish it and I'm leaning towards doing that when I will be close to redoing all of the bed liner.

What did you use on the black trim pieces? It looks good.

A lot of elbow grease and some scratch out type product. It looks 80% good but in certain light shows a lot of fine swirl marks so I will be going back over it with some 3m rubbing compounds.
 
Scored big today! I bought locked full float axles, the e brake, beefier front sway bar, and some other goodies off an LX450. I've basically given up on trying to find them that way, but boom! There it was. A fresh arrival at a local yard. Unfortunately someone copped the rear actuator and wiring connector for it in the couple days it had been there, but overall I got most of everything else needed.

In addition to fully rebuilding both axles and re gearing them, I'm looking to add diff armor, drain plug protection, and knuckle ball gussets. I'm also going to sand blast them and repaint them /powder coat all of my control arms gloss black. I'm kind of tempted to go with wheel gray on the axles maybe yellow zinc coated bolts or everything in stainless. I know it'd be a kind of unnecessary, but I think it would look pretty slick.

I also bought all 5 wheels because they are in overall decent shape. I'm contemplating putting them on my cruiser and ditching the FJ wheels so I don't have to run wheel spacers, but that would also require new 16" tires. If I don't use them, I'll probably get them powder coated "Toyota dark gray" and let my dad put them on his beige Fj40.

Then I also figured I'd buy the headlights and grille as they are all in great shape. I like the grille design a lot better on the LX and I'm contemplating switching all of that out for a more factory look compared to my depos.

I also snagged both driveshafts so I can rebuild them and put them on my cruiser as mine are original and have some slop.

Overall I'm super excited and bummed I have to go back to school next week, but at least I'll end up with some time to figure out everything I'll need.


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Several questions I am going to have to figure out in regards to the locker install...

Considering I have a '92, none of it is pre-wired.

Are the wiring connectors for locker parts available so I can build my own harness? I tried to grab everything I could, but was beat to the rear actuator wiring. I know my gauge cluster does NOT have the cut outs for the lockers to light up. I can't imagine cutting them out of the old cluster and somehow fitting them to mine, but I am needing to figure out a similar way to notify me when they are "flashing" or "locked".

I didn't grab the master cylinder, but I did grab the entire e brake set up. Are the master cylinders the same between drum and disk models? I've read that they are and aren't so I am not for certain but I definitely want the best performing brakes I can get out of this set up.
 
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Finally about done cleaning. I spent several hours yesterday power washing the underside, followed up by some time at the car wash this morning and detailing afterwards just to get hit with multiple rounds of rain. Now that I look at the picture of these jacks I probably should have done it a bit differently.View attachment 1517704

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In the top picture you have the red cover for your air line connector...where did you get it and do you have a part number??? Thanks!!!
 
In the top picture you have the red cover for your air line connector...where did you get it and do you have a part number??? Thanks!!!

I don't have a part number. It's just a cover for a hydraulic line that I found at Tractor Supply Co one day. They have black and red. The red ones fade pretty quickly and I find myself swapping them out but the bright color is nice because it reminds myself and friends to put it back on.
 
The other day I took a break from working on swing outs and built a rack that holds two yakima high rollers on my yeti cooler swing out. I was getting a little annoyed with having to fold my Northshore down to get into the back of the cruiser if I was just hauling one or two bikes. I also wanted a little more clearance after knocking my bike off on a rock ledge last summer. With this rack I have 40" of ground clearance.

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And yesterday after I cleaned the garage and shipped out all the swing out kits, I finally finished my hi lift mount for my swing out.

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Pulled off my receiver hitch today and cut out the rear cross member. I was hoping to replace it with some 2x4x1/4" tubing, but I really need a 2x5" to really fill in the molded lines on the factory bumper wings.

Pretty crazy how poorly the factory cross member handled a receiver hitch that was only used to carry bikes...usually no more than 2.

Seeing most of the bumper has me awfully tempted to just cut off the rest and build a full bumper, but with class I just don't have the time. Hopefully this will get wrapped up next weekend.

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I also cut my exhaust back and dumped it behind the rear axle. I added a new exhaust hanger for it, and a slight downturn to it so it wouldn't spray anything but the ground. Looks a lot better and I'll stop dragging it which is a big perk.
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