Builds Flooded 1981 Toyota Pickup Revival & Sprung Under FJ80 Axle / Dolphin RV Dually Axle Swap Build Bonanza on 4Ds (2 Viewers)

[Lucille]

Im bored offshore, so I figured i would throw together a build thread for my next s***box in the fleet and post it here on Mud. Some back story on this '81. This truck was someone's baby at one point. So many nice 80s touches throughout, i.e aftermarket lights everywhere, wooden cup holders, ladder bars, Skyjacker stiff lift, etc. At some point 15+ years ago it was flooded over the roof and sat as a parts truck ever since until i picked it up. Truck has rust on the body in the usual place around the windshield, floors, bed, etc. Frame is 98% solid though. Build will be using parts i have laying around including the drivetrain from an 88 Dolphin RV i picked up from the same gentleman.

On to the build plan. I am breaking this up into two phases.

Phase 1 (Get it running and driving again):
22re swap from the Dolphin (97k miles)
5-speed L52 (from original truck)
4.7 Geared t-case with twin sticks
Get it wired using the complete 22re harness from the dolphin
Get the AC to work (Truck was original AC truck)
Dual diaphragm brake booster from the RV.
2nd Gen 4runner gas tank swap from 1992 4runner.
4.37s (what came in the truck)
36" TSLs
Rebuild the warn winch just to see if i can.

Phase 2:
Complete suspension redo
RUF up front or Marlin 5" Lift Springs
57" ford rears
Spring under
Converting the Dolphin RV full float dually axle to single wheel using FJ80 FF hubs. (~63" WMS)
E-Locked FJ80 front sprung under
Crossover-ish steering with IFS box and power steering. Plan on using a Slee high steer arm on the passenger side in double shear with the OEM arm on the passenger knuckle and a RHD arm on the drivers side to level out the tierod.
05+ Tacoma bigger brakes front
FZJ80 Factory Rear backing plates and discs.
40s of some flavor on beadlocks of some type
5.29s and some locker in the rear. E-locked front.

Some pics of all the junk i have acquired so far. I bought a total of 5 toyotas from the same local gentleman. His wife made him clean up some of his yard. Sold two (The 87/85) already and trying to sell the third (92 4runner). Parted out the Dolphin RV and am building the 81. Also picked up a wrecked 98? tacoma with a 3rz/auto, and an 85 4runner with a bunch of new old stock marlin parts which i plan on using as much as possible.

First up is the '81 as it sat when i picked it up. 3" Body lift and all.

Also picked up these two, an 87 4wd and 85 2wd as well.

The red one cleaned up and i got it to run the 1st day. A little shine job and sold it.

Also picked up a 92 4runner 4wd with factory 4.88s. Could never get it to run. For sale currently.

Onto the donor for the drivetrain. 97k 22re/auto equipped dually dolphin RV, minus the RV. Kept the 22re, full wiring harness, rear axle and am selling/scrapping the rest.

Wish i could have kept the floor out of the dolphin to use as patch panels for the 81 floor. It was in perfect shape.

to be continued....

 

[Lucille]

The 97k mile 22re. Took a little bit of marvel mystery oil and some prybar action but i got it to free up and eventually run pretty dang well. Smokes some but the smoke is less and less every time i run it. The rings are starting to heal some.

The 81 22r engine has seen better days.

Rolled the 81 into the shop.

22re sitting in and 3" body lift removed. The aluminum body lift pucks fused themselves to the steel bolts so a sawzall was used to chop them all out. That wasnt fun.

Craigslist rebuilt the L52. Internal condition unknown. Installed new output seal, clutch, resurfaced flywheel, slave/master cylinder. Fun fact, a 93/94 22re has a ~1/2" larger diameter clutch and flywheel than earlier versions.

22re installed. I couldnt fit the factory AFM air cleaner box so i deleted it and added 10hp with an open air filter i had on the shelf with a cheap amazon adapter. Even the factory 81 radiator overflow and washer resi fits.

82/83 cluster that i had on the shelf that im using.

Some of the wiring diagrams i used to wire in the cluster. These are the outputs from a 83 cluster.

For the 88-ish cluster harness plugs:

 

[Lucille]

Final plug pinout.

Completed 22re swap. Used the RV radiator, RV booster, RV coil/igniter. Used the 4runner master cylinder.

1st gen tacoma seat sitting on the rotted out floor.

Twin sticks and an old school Longfield shift knob round out the shifters. Ill need to bend the L52 shifter some to clear the twin sticks.

Finally found a use for the inclinometer i picked up from a buddy.

Fun fact is that a 2005 VW Jetta TDI downpipe and resonator are a perfect fit for this truck.

Took for its first test drive yesterday without any working brakes. Also put a grey scotchbrite pad and some water to it and boy did it clean it up real nice. 36" TSLs and some 15x10 micky thompson wheels give it that classic look.

After the test drive i figured out the T-case wouldn't shift into 4wd. i think the shift rails hit the back of the transmission. The L52 doesnt have a huge pocket for the rails if they extend past the face of the t-case. Ill pull it later on when i get further into phase two of the build.

 

[Lucille]

Messed with the brakes. Had to disconnect every brake line connected and blow brake clean through them to clear them out. Finally got fluid to reach each end. Installed new(er) SS brake hoses and tried to bleed them. Got good pedal, but really only the front right caliper is trying to do something. Ill need new calipers as these are more than likely stuck from sitting and rusting for all these years. Now the debate is to spend money on this axle knowing ill be swapping in a FJ80 front, or just waiting. Ill have to check my parts stash to see if i have some decent SA calipers or try and work these to see if i can get the pistons unstuck.

Also pulled the dually axle into the shop. Just need some FZJ80 rear hubs to convert it over to 6x5.5. The housing appears to be beef in comparison to the stock axle.

Picked up some goodies for a couple projects a few months ago. The 3UZ is for a flooded SC430 i picked up at auction. The engine had a hole in the block after the last hurricane.

The FJ80 front is for this truck. Its missing the wheel hubs, calipers, etc, but is an e-locker. Score.

 

[Lucille]

I then picked up the final piece of the puzzle for the dually 8" rear axle, a FJZ80 9.5" full float rear axle. I am using the hubs and brakes off the 80 axle for the dually axle. This should put me around 63" wide to match the front. I do realize the 9.5" axle is stronger, but i dont want to deal with the offset diff and/or move the gas tank. I think the 8" should be plenty strong for 37s.

Pic of the wrecked 98? taco i scored for free. Has a 3rz auto ill set aside for a rainy day. Pulled the complete harness, AC stuff and some other parts.

 

[Lucille]

Scored another parts vehicle for the build. 85 4runner that is a tad bit rusty. Has some good parts to it. LC brake upgrades up front, 22re, W56, top s*** t-case, 4.88s, PS, AC, good top, etc. Also included was a bunch of suspension upgrades for the 81. It has a full marlin kit with leaves f/r, 5150 bilsteins, new IFS box, a disassembled front axle, and a bunch or stuff this guy bought new and never installed.

The RE is locked up solid in the 4runner, but has a good shifting W56 and t-case. Apparently has a blown headgasket. Ill try (not hard) to see if i can get the engine unstuck. I plan on using the rear marlin springs up front along with the shocks, hangers, etc that came with the kit. Ill also swap in the w56 in place of the L50/52. I have to pull the t-case anyways.

As i picked it up.

Super crusty

It was a sharp looking runner before the rust and neglect took over. Love me some BFG KM1 tires. I did get them to hold air to roll it off the trailer.

So many parts included.

 

[Lucille]

Been working on the truck some once i got back from offshore before thanksgiving. Stock axles and suspension removed. Frenched in the rear front spring hangers and got the full float dually axle bolted in. Swapped on the FZJ-80 full float rear backing plates with some adapters i made to weld onto the RV axle. Came out pretty slick. Hubs, brakes, backing plates are all FJ80 s*** now and bolt on.

Going to crazy low so i frenched in the hangers. Should lower it an extra 1-2 inches.

It also let me cut out some of the only frame rot this truck has.

Also dont french in hangers with 400lbs of s*** in the bed while not supporting the rear portion of the frame. :homer:

Got it back straight and fully plated the frame as shown above. Im dumb.

Anyways, now onto the cool stuff. The RV full float axle with FJ80 parts.
Bolted in spring under with a Ruffstuff kit i had used on the shelf. Pinion will be adjusted once i can get it on all 4s and see what the driveline angle needs to be with the doubler and W59 installed. I am using the stock perches and they are the same width/spacing as the stock stuff.

Orbit eye shackle hangers for the rear that i also had used on the shelf for years. You can see the theme here. Re-use as much s*** as possible. I cut the 6" shackles out on the table. The rears are tacked on for future dialing in of the shackle angle.

Made an adapter plate to weld on the FJ80 backing plate. The center hole is sized for the spindle on the RV axle. It slips over and the wheel hub and caliper center it onto the spindle for welding. I also deleted the ABS sensor hole.

s*** pic but you get the idea. All bolted up. Now i have 6x5.5 bolt pattern for the wheels with factory rear disc brakes.

to be continued...

 

[gnob]

those dash notepads are mine
i can send you an 86 ewd pdf if you can make use.

 

[Lucille]

I test fit a 39" tire from a friend to check things. Had to do some trimming, but i want it lower. So may pull a rear leaf to start after i get it on its weight and see the stance. Ill maybe bob the bed some to get rid of the tree damage on the drivers side.

Now onto the front. Pulled the front axle and leafs as an assembly.

Disassembled the front and washed off the radius arm brackets and spring buckets mounts. That sucked, but its ready for some spring under leaf mounts.

Spoiler, also picked up a new resto-mod project.

I used some Marlin 5" front lift springs. for the front lift. Not sure ill be using them in the end, as id like some rears up front, but we will see. A bud is dropping off some used 4" TG rear springs from his 4runner so i may end up using those, or find some 3rd gen 2wd rears to use the main leaf. Still TBD.

 

[Lucille]

Now onto the front. As you can tell, im using an FJ80 front with a high pinion e-locker third. Both need rebuilt. I started with the stock 29" spring spacing and it was a little too close for comfort to the diff, so i widened the leafs out to 30.5". This is about perfect for spring under on a FJ80 axle. I then started slicing and dicing the passenger tube to get everything to lay nice and flat. The FJ80 housing is a bastard of a housing with some square tube and some round tube, but i made it work.

First attempt at 29" spacing. I wanted to reuse the Sky's offroad design hanger i had on the shelf. It was easy to cut up to 31.5".

Springs are Marlin 5" HD springs that i got with the rusted out red 4Runner. As you can see, they are pretty close to the diff. This was my first notch of the housing. Leaves little room for a u-bolt or stud.

So i cut the front spring hanger and moved around the spacers on the shackles to get the new hanger width of 30.5". Seems to work out well. Upper plate will be welded and gusseted to the Housing on both sides. The lower plate has 3 positions for the leaf spring center pin just in case i need to move the axle around 1" either way. U-Bolts are from a newer tundra IIRC. Not sure why i had them on the shelf, but they should work out nicely.

Pretty close to the e-locker actuator but everything clears and the third bolts in easily.

I cant wait to see it on its weight. I have a feeling the axle is going to get close to the oil pan. The pan on here is from the RV and is for a 2wd. I can swap it with a 4wd pan to get some more vertical clearance and also lift the drivetrain an inch or two, if needed. Helps with the flatbelly too.

And this is how i will leave it for 4-5 weeks as im back offshore. Its essentially pretty close to being a roller again so i can check all the clearances. I have a set of rear 3" TG springs that im getting from a buddy and can use those if these Marlin ones dont work out. Ill leave the front spring hanger loose / lightly tacked on until i make that call. I need a new/used spindle for the FJ80 front, then i can at least bolt everything back on to make it a roller again. Still deciding on 37s or 40s. Probably 40s. I didnt want to use 5th gear anyways.

Also check out this cool Bandeirante that i saw at the Heliport this morning. Pretty clean unit with fugly square headlights. Toyota made the FJ40 in Brazil until the mid-90s i think. This one is a diesel and a 5-speed but still leaf sprung all around.

 

[Lucille]

those dash notepads are mine
i can send you an 86 ewd pdf if you can make use.

Yessir they were. I think i found them on Marlins forums. Worked great for the most part. The RV wiring may be a little different but i pieced it together to get it all to work in the cluster.

 

[gnob]

digging it. also a fan of the fjc rims

consider running the rear shackle upper mount through the frame as well, to get lower.

 

[Lucille]

My neighbor picked up this 89 4runner on a trade for some work he did and i ended up buying it off of him for what he was owed. Not the prettiest but i got it run and drive with a new fuel pump and a gas tank cleanout. Bought it flip, because as you can tell, i dont need any other projects, so i did some horse trading with a fellow toyota enthusiast and picked up the Trekker. Its an 81 without a drivetrain. Always wanted one so here we go. I may start a new thread on it once i get going on the drivetrain swap.

This thing is solid. The drier climate helped keep it in one piece. Fiberglass is also in nice shape.

Washed it before i took it off the trailer. Cleaned up nicely.

And the donor. 97 Tacoma with a 3rz/5-speed, etc. Slightly wrecked. Plan is to use the 3rz out of this tacoma in the trekker and use the w59 with an adapter and w56 bellhousing to bolt to the 22re in the flooded truck. I will use the w56 and t-case from the red 4runner with the w59 bellhousing in the Trekker. My plan is to body on restore it for the most part. Clean up the frame, rebuild the axles. 33s on the cleaned up wheels on the red 4runner for now. The trekker is an AC, PS truck, so hopefully i can get it all going. Maybe a repaint down the road but for now some fresh graphics from Angie at BL Vinyl.

 

[Lucille]

And the 89 4runner i traded for the trekker.

 

[Lucille]

digging it. also a fan of the fjc rims

consider running the rear shackle upper mount through the frame as well, to get lower.

Yeah its a bud's spare for his crawler. Ill get it on all 4s and see what it looks like. Ill start with pulling leafs first. The rear shackle hanger in the rear happens to land right where the rear tire crossmember is so frenching them into the frame is going to suck.

 

[gnob]

Yeah its a bud's spare for his crawler. Ill get it on all 4s and see what it looks like. Ill start with pulling leafs first. The rear shackle hanger in the rear happens to land right where the rear tire crossmember is so frenching them into the frame is going to suck.

right. because the longbed. im used to looking at 4runner chassis.

 

[Lucille]

Ordered a Slee high steer arm for the passenger side. Along with a knuckle rebuild kit and some wheel bearings while i was ordering stuff..
Im hoping i can have the drag link and tierod above the leafs with this setup and have it in double shear. The plan is use 3/4 or 7/8" heims for the steering linkages.

Also ordered a RHD double steering arm for the drivers side knuckle from Cruiser Parts LLC. I will have the tierod sit above the steering arm and weld a top plate above the heim to put it in double shear as well.

In my head it should all work. We shall see.

 

[cruisermatt]

your trailer sure does get a workout.

 

[Lucille]

your trailer sure does get a workout.

If you only knew Matt. Once i get back from offshore i have to go pickup a couple other trucks for parts. Im fighting the urge to get an 84 Buick Regal G-Body as well. Im weak.

 

[littlevulture]

Now onto the front. As you can tell, im using an FJ80 front with a high pinion e-locker third. Both need rebuilt. I started with the stock 29" spring spacing and it was a little too close for comfort to the diff, so i widened the leafs out to 30.5". This is about perfect for spring under on a FJ80 axle. I then started slicing and dicing the passenger tube to get everything to lay nice and flat. The FJ80 housing is a bastard of a housing with some square tube and some round tube, but i made it work.

First attempt at 29" spacing. I wanted to reuse the Sky's offroad design hanger i had on the shelf. It was easy to cut up to 31.5".

Springs are Marlin 5" HD springs that i got with the rusted out red 4Runner. As you can see, they are pretty close to the diff. This was my first notch of the housing. Leaves little room for a u-bolt or stud.

So i cut the front spring hanger and moved around the spacers on the shackles to get the new hanger width of 30.5". Seems to work out well. Upper plate will be welded and gusseted to the Housing on both sides. The lower plate has 3 positions for the leaf spring center pin just in case i need to move the axle around 1" either way. U-Bolts are from a newer tundra IIRC. Not sure why i had them on the shelf, but they should work out nicely.

Pretty close to the e-locker actuator but everything clears and the third bolts in easily.

I cant wait to see it on its weight. I have a feeling the axle is going to get close to the oil pan. The pan on here is from the RV and is for a 2wd. I can swap it with a 4wd pan to get some more vertical clearance and also lift the drivetrain an inch or two, if needed. Helps with the flatbelly too.

And this is how i will leave it for 4-5 weeks as im back offshore. Its essentially pretty close to being a roller again so i can check all the clearances. I have a set of rear 3" TG springs that im getting from a buddy and can use those if these Marlin ones dont work out. Ill leave the front spring hanger loose / lightly tacked on until i make that call. I need a new/used spindle for the FJ80 front, then i can at least bolt everything back on to make it a roller again. Still deciding on 37s or 40s. Probably 40s. I didnt want to use 5th gear anyways.

Also check out this cool Bandeirante that i saw at the Heliport this morning. Pretty clean unit with fugly square headlights. Toyota made the FJ40 in Brazil until the mid-90s i think. This one is a diesel and a 5-speed but still leaf sprung all around.

That front spring under is sweet, I'm planning on converting my front axle to spring under as well as I get stuff rebuilt. Everything has pros and cons and it seems like the pros of spring under are always ignored because it reduces the ground clearance under the front axle.