DIRTBIKEUSA’s Alaska Cruiser build thread

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Wiring in the led bar and fog lights. I didn’t like the round switches the kit came with the switches I bought all most fit so I had to file a it to get them just right. And they are back lit on. 😎

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AUX battery wired in and tested. Everything works as I should.

I decided to buy a refurbished alternator and will send that unit off to increase the amps. That way if it burns up I still have my OEM unit.

I could not spin the battery around because of the cable and auto relay box geometry.

Once the winch is out in I will see where the fog lights will mount.

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Wiring in the led bar and fog lights. I didn’t like the round switches the kit came with the switches I bought all most fit so I had to file a it to get them just right. And they are back lit on. 😎

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I think I was looking at those same switches on Scamazon the other day. Not that I'm afraid of a little trimming, but I think I'm going to keep looking for OEM Toyota switches for fog lights... gives me something to keep my eye out for in the PickNPull yard.
 
I think I was looking at those same switches on Scamazon the other day. Not that I'm afraid of a little trimming, but I think I'm going to keep looking for OEM Toyota switches for fog lights... gives me something to keep my eye out for in the PickNPull yard.
I will see how they work out. I think they look good. People may turn their nose up but I can’t complain for $8 or whatever I spent on them.
 
Waiting for the bacon to cook and I was going through the owners manual. Inside was the folded up dealership sticker. Pretty neat if you ask me.

The sticker says it came with keyless entry and alarm. I don’t have the clicker so I have to track down how get one. I seen a thread on an adapter for an aftermarket control unit. I don’t know much about keyless entry or alarms so not sure where to start.

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The swing outs so far. I went another direction with the spare tire mount. The arm was too high and I want the spare to rest on the bumper when traveling. Cut, grind, and re-weld. I can always add more metal.

Another member was having issues with the OEM spare tire hoist. They were missing the tool. Surprise suprise! Me too. So I cut a slit in a HF 1/2 socket 3/8dr then Hammered in a strip of sheet metal and bam! New tool for the spare tire bag.

Another storm is coming in so more time to gather hardware to mount the spare. I have some 1/2 bolts but I think they will be too short.

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Sun roof leaked a bit last night and the 26in bike tube came today. So I cut it up and slipped it in. I might have cut it too thick so I might have to trim it down I will see if it works to keep it dry inside after tonight’s forecasted rain.

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Sun roof leaked a bit last night and the 26in bike tube came today. So I cut it up and slipped it in. I might have cut it too thick so I might have to trim it down I will see if it works to keep it dry inside after tonight’s forecasted rain.

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I need to look up the bike inner tube remedy for the sunroof, mine isnt leaking but the outer seal is probably 25+ years old. My sunroof rattles when i pull the inner shade all the way back, i need to look at that as well.
 
The swing outs so far. I went another direction with the spare tire mount. The arm was too high and I want the spare to rest on the bumper when traveling. Cut, grind, and re-weld. I can always add more metal.

Another member was having issues with the OEM spare tire hoist. They were missing the tool. Surprise suprise! Me too. So I cut a slit in a HF 1/2 socket 3/8dr then Hammered in a strip of sheet metal and bam! New tool for the spare tire bag.

Another storm is coming in so more time to gather hardware to mount the spare. I have some 1/2 bolts but I think they will be too short.

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I wouldnt be comfortable with a fuel can sitting that low on the rear bumper but thats just me. Great work on the bumper though.
 
I need to look up the bike inner tube remedy for the sunroof, mine isnt leaking but the outer seal is probably 25+ years old. My sunroof rattles when i pull the inner shade all the way back, i need to look at that as well.
I found that after I cut a thin 3/16 or so strip out and seated ALL THE WAY down in the crease AND lubed up the seal AND adjusted the sunroof as far forward as possible it set nicely back into the correct spot.
 
I wouldnt be comfortable with a fuel can sitting that low on the rear bumper but thats just me. Great work on the bumper though.
Why? If they rear end me I will just drive off and leave them on fire.
 
I’m standing in mud while welding, reminds me of deployment. Project is really starting to take shape.

I really need to start the roof rack project. I think I have the material but I need some kind of way to attach it to the roof.

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I'm just going to say it, and I mean no offense, but there is no way those swing outs are making it to Alaska...
 
What's your plan for a latch on the carrier? That tire is gonna rattle/squeek like crazy. Might wanna put a d-rings on each side of the tire on the bumper and a ratchet strap to pull it tight to the bumper. That squeak and rattle would drive me nuts 2 min into a trip, much less the distance and roads you're planning on.

Keep on keeping one though!!! Digging how your repurposing things. I've done that a lot myself through the years, latest was a rack in the back of mine from a bed frame and a closet shelf.
 
What's your plan for a latch on the carrier? That tire is gonna rattle/squeek like crazy. Might wanna put a d-rings on each side of the tire on the bumper and a ratchet strap to pull it tight to the bumper. That squeak and rattle would drive me nuts 2 min into a trip, much less the distance and roads you're planning on.

Keep on keeping one though!!! Digging how your repurposing things. I've done that a lot myself through the years, latest was a rack in the back of mine from a bed frame and a closet shelf.
Yeah I thought the rattling as well. I mentioned that I left the ends open for drains and tie downs a few posts back.

Free steel is the best steel! It’s kinda funny that things show up when you need them.

I was thinking the EXACTLY the same thing with the old bed frame. I got one leaning up against my fence. It’s spring hardened steel so welding is going to be kind tricky. I was going to use the square 1/8 and spot weld in the holes of gussets and spars.. idk if I can weld the frame material to itself without it cracking.
 
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Yeah I thought the rattling as well. I mentioned that I left the ends open for drains and tie downs a few posts back.
I was picturing a d ring welded to the top of the bumper above the bumper bolts and another one above the receiver so you can cinch it down tight to the top of the bumper. That will help, but still gonna have it rattle forward and rear word with the pin/hinge like that.
 

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