It has been a while since my last post. My cousin just moved to China for 6 months and would like to read up on my progress so here goes
I have been out several times now and am more comfortable with the rig now. I built a 2 x 4 x 1/4" wall rear bumper and added square tube for a tire carrier. Works great. I didn't take any build pics. Got burned out on posting. I take some pics later.
My carb was not working well at all. I replaced with with a rebuilt quadrajet and it runs awesome now.
I have a 1.5" drop pitman arm. It is 5.5" long center to center. I set my steering stops where the birfs maxed out. When I turn my steering wheel all the way to the steering stops I can turn the steering wheel another 1/4 turn or so. That puts a lot of pressure on the steering rod ends. I worry I am going to break something. So I am hunting for a shorter pitman arm.
The brakes are still an issue. I upgraded to a 9" dual diaphragm brake booster. It stops way better than before, but I can't lock up the tires on dry pavement (low vacuum from performance cam). I have the proportioning valve dialed all the way and the back still locks up before the front. I can live with it for now. I did lots of research and there might be some better calipers than the V6 4Runners and Monte Carlos. I don't have the info with me right now, but there is a different front caliper with slightly larger pistons (read about them in the truck forum) and you can use '85 Trans Am rear calipers in back (not positive on all the years). They are 1 7/8" pistons. Better than 2.5" Monte Carlo and are set up with a cable operated parking brake. This part can be removed.
Mounted a CB between the front seats and a powered speaker on the roll bar. Now I can actually hear the CB

I am setting up a stereo also. Later on I will fab up some better mounts for them instead of plywood and 2x2's. It's ugly, but it works for now. I plan on a Metal Tek family cage and will mount the radios between the spreaders.
One think I don't like is how far down the tcase sits. I put it up as high as I could without cutting into the gas tank cavity. It is 2" lower than stock. Nothing I can do about it except a body lift or a different gas tank. I thought about adding a fuel cell in back, but then I lose the ability of a rear seat. I want a rear seat so it's not an option.
I am getting ready to buy lift springs. I have 5" shackles now and 33" tires. They clear with all the body cutting I did. I plan on 35" to 37" tires later on. From the experience I gained I think I can clear 35s with a 2.5" lift up front. To even out the rig with all my trail gear I need 4" in back. Trying to find the right set of rear 60 series springs for the back and 2.5" front 40 springs that won't give me vertical shackles has been a PITA. If my fronts weren't flipped I could use the longer set that CCOT or SOR sells (don't remember which). Can't flip them though because the long side is longer. That would push my axle too far forward. Contacted Alcan and those are too pricey.
That is where I am now. Have to finish installing the radio and fabbing some speaker boxes before a snow run on Saturday.