Its a Tundra yes, but why did you do that? (2001 Toyota Tundra Build) (1 Viewer)

[smokeysevin]

This is just the beginning but I am prepping my supercharger setup for install and saw a bunch of questions/discussion about that topic so I am going to outline where I am currently.

2001 Toyota Tundra SR5 Access Cab V8 2WD 4WD

This "build" will be tame by most measures but will (hopefully) end up where I always wanted it to. It is also not going to have lots of cool travel pictures, its pretty much a home depot runner and occasional beach truck/jetski tow rig. The only reason its getting worked on at all is because I finally managed to cobble together all the parts I needed to finish the 4wd swap and thought "if I am going to do the work, I may as well do it how I wanted"

The truck as it sits now is a mutant hodgepodge of miss matched parts, 16-32 year old Sean was a real idiot. Lots of loose ends to tie up.

Recent maintenance has been:

2023
2007 Sequoia rear brake conversion and parking brake install
Motor and trans mounts
Rear axle rebuild
Pressure washed underbody and engine bay
Spark plugs
Starter motor
Fan and fan clutch
Heater hoses and valve replacement
Winch ground wire replacement
Reman'd front brake calipers and fluid flush
Front Brake pads
Driver's side outer cv boot
Double cardan center driveshaft joint rebuild

2022
Lower control arms
Lower ball joints
Upper uniballs
Upper control arm bushings
Inner and outer tie rods ends
Lower control arm pivots
Rear leaf spring rebuilt
Transmission service
Transfer case service and shifter lockout removal
Radiator and coolant
Door seal replacement

Current maintenance/work required:
Valve cover gasket replacement
Charcoal canister/evap system repair
Seatbelt tensioner replacement
Supercharger install
Flex fuel conversion
Intercooler install
Ac system rebuild
Winch wiring rebuild

Spec overview: 2001 Toyota Tundra SR5 2WD 4WD

Engine
ASP Underdrive Pulley: (Home - https://www.autospecialties.com)
Ported Upper and Lower Intake Manifold: (DIY)
Throttle Body Coolant Reroute: (DIY)
05-06 Intake manifold swap: (DIY)
SSAutochrome Shorty Headers and Y Pipe: (http://ssautochrome.com/level.itml/icOid/1430)
Magnaflow 2.5” Center In, Side Exit Muffler (Dumped Before Axle):
Magnaflow 2.25” “Spun Cat” Catalytic Converter:
Champion Cooling Aluminum Radiator: (2000-2001-2002-2003-2004-2005-2006-Toyota-Tundra - https://shop.championcooling.com/2000-2001-2002-2003-2004-2005-2006-Toyota-Tundra)
HPS Silicone Radiator Hoses: (HPS Black Reinforced Silicone Radiator Hose Kit Coolant Toyota 99-03 Tundra V8 - https://hpsperformanceproducts.com/products/hps-black-silicone-radiator-coolant-hose-kit-toyota-99-03-tundra-v8?_pos=3&_sid=8d6ce3a24&_ss=r)
URD Maf Calibrator (Untuned) : (URD MAF Sensor Calibrator - UNIVERSAL - https://www.urdusa.com/urd-maf-sensor-calibrator/)
URD Rear O2 Sensor Simulator (high flow cats kept tripping the CEL)
Ebay Air Intake
Volant Donaldson Power Core Air Filter

Drivetrain

Transmission/Transfer Case/Driveline
2004 A340F 4wd Transmission
Radesigns Winters Shifter with electronic control system (Winters-Elec. Control Kits - http://www.radesignsproducts.com/winters-elec.-control-kits.html)
2000 J Shift Manual Transfer Case
Radesigns Twin Stick Shifter (Triple & Twin Sticks - http://www.radesignsproducts.com/triple---twin-sticks.html)
Hendrix Motorsports Billet Aluminum Carrier Bearing: (https://www.polyperformance.com/hen...um-carrier-bearing-support-for-toyota-cbs-001)

Front End
2000 7.5” Clamshell Front Differential
4.56 Yukon Gears
Toyota Supra Limited Slip
ECGS Solid Bearing Spacer
Locked ADD Actuator
94.5 Tacoma Manual Locking Hub Swap
Aftermarket Spindle Hubs
OEM Wheel Bearings and Seals
OEM Manual Lockout Hubs
DTA Tacoma Outer Axles
OEM Tundra Inner Axles

Rear End
GM 12 Bolt Truck Rear Axle
Yukon Heat Treated Axle Shafts
Mark Williams Enterprises Steel Bearing Cap
Mark Williams Enterprises 1310 Yoke
Low Range Offroad Toyota to 1310 U Joint: (https://www.lowrangeoffroad.com/131...t-u-joint-universal-joint-tdi-1310-toyuj.html)
Detroit Tru-Trac Differential
Yukon Gear 4.56 Gears
Moser Bearing Support Diff Cover

Brakes
Brake Hydraulics
Toyota 4runner Dual Diaphragm Brake Booster
T100 1-Ton Master Cylinder
Wilwood Adjustable Proportioning Valve (Wilwood 260-12627: Proportioning Valve Knob Adjust - JEGS - https://www.jegs.com/i/Wilwood/950/260-12627/10002/-1)
LSPV Delete
Wheelers Offroad Extended Rear Brake Line (https://wheelersoffroad.com/shopbyv...eight-to-2-lift-tf-bline-05-red-or-black.html) Currently too short

Front Brakes
2006 Tundra Brake Update

Rear Brakes
Custom Brake Caliper Mounts
2007 Toyota Sequoia rear brake calipers and rotors
Custom hub centering rings
Wilwood parking brake calipers

Suspension

Front Suspension
Donahoe Racing (Icon) Extended Travel Coilovers (Products - Icon Vehicle Dynamics - http://iconvehicledynamics.com/shop/individual-accessories-components/36-2000-2006-tundra-ext-travel-front-coil-over-shock-kit.html)
Camburg Uni-Ball Upper Control Arms (https://camburg.com/shop/suspension...wd-00-06-performance-1-00-uniball-upper-arms/)
Sway Bar Delete
Total Chaos Fab Steering Rack Bushings (Toyota Tundra 2000-2006 POLYURETHANE STEERING RACK BUSHING KIT | TOTAL CHAOS FABRICATION - https://www.chaosfab.com/accessories/2000-2006-Tundra-Urethane-Rack-Bushings-97701)
Total Chaos Fab Double Shear Plates
Total Chaos Fab Spindle Brace
Total Chaos Fab Uniball Adapters and Misalignment Spacers

Rear Suspension
Deaver G57 Spring Over Leaf Springs (https://deaverspring.com/product/tundra-2wd-4wd-1999-2006-10-leaf-spring-1-inch-lift-rear/)
Custom Rear Cantilever Suspension
FOA 10” Travel Remote Reservoir Shocks (F-O-A 2.5 Inch ID Reservoir Shock, 10 Inch Travel » F-O-A | First Over All Off Road Shocks - https://f-o-a.com/shop/f-o-a-2-5-inch-id-reservoir-shock-10-inch-travel/)
Airlift Dominator 2600 Airbags (Dominator D2600 Single 1/2″ port – 58616 - https://www.airliftperformance.com/product/58616/)
Daystar Air Bag Cradles (https://www.4wheelparts.com/p/daystar-air-bag-cradle-ku09140bk/_/R-BKCG-KU09140BK)
G2 1.5” Wheelspacers

Utility
SOS Custom Bedcage
TT Motorsports “Harbor Freight” Jack Skid (TT Motorsports 1.5 Ton Floor Jack Skid Plate and Quick Release Mount | tt-motorsports - https://www.tt-motorsports.com/product-page/tt-motorsports-1-5-ton-floor-jack-skid-plate-and-quick-release-mount)
SOS Quick Release Fire Extinguisher Mount
US Cargo Control "Airline" L-Track (L-Track - Heavy Duty Airline Track Tie Down - https://www.uscargocontrol.com/Aircraft-style-seat-track-6-ft)
Viair 5 Gallon Air tank (5.0 Gallon Air Tank | VIAIR Corporation - https://www.viaircorp.com/air-tanks/5gallon)
MF1050 Air Compressor (MF-1050 Tsunami Air Compressor - https://masterflowair.com/products/mf-1050)
Jim's Machineworx Battery Terminals
1000W Renogy pure sine wave power inverter
40MM Ammo Cans

Tools
Required for service/repair

Recovery Gear
Straps
Shop Towels
Solar Charger
First Aid
Air Hose
12k Winch

Fluids
Oil
Trans Fluid
Diff Fluid
Brake Fluid
40MM Ammo Can Locks

Lighting
Aftermarket “Black” Headlight Housings (http://www.ajpdistributors.com/0001020304to3.html)
TRS Morimoto BI-LED Projector Retrofit (https://www.theretrofitsource.com/bi-led-morimoto-m-led-headlight-projectors-kit.html?preselect=52976,54340,49863)
Nilight 7” LED Spot Pattern Lights
Clear Laminx
Amber Laminx
Orange Laminx
Nilight 2X3 18W Dust Lights
Nilight 2X3 18W Reverse Lights
KC Hilights Cyclone Amber Rock/Service Lights (KC® Cyclone LED Rock Lights / Accessory Lights - Multi-Colors & Lenses | KC HiLiTES® - https://www.kchilites.com/light-type/led/cyclone.html)

Interior
Alpine Android Auto Head Unit (iLX-W650 Bundle with KTA-450 - https://www.alpine-usa.com/product/ilxw650_kta450_power-duo_package)
Firestick Antenna (CATALOG Main Page (Frame Setup) - http://www.firestik.com/CatalogFrame.htm)
Sony Xplod 800w Amp
Kicker S8L5 Subs under rear seat
Infinity Reference Speakers
Raamat Sound Deadner
Switchpros SP9100 (https://store.switchpros.com/sp-9100-switch-panel-power-system/)



Exterior
Roadrunner Fiberglass Front Fenders
Chopped and Pulled Rear Fenders
Rear Bumper Delete
Custom Rear Hitch
2006 Tundra Grille

Long term goals are for long travel front end while retaining 4wd, rear glass, full paint, new seats (probably prp) 4.88's and 35s all around (which will involve a swap to a 9" FF Rear), and custom front bumper.

Sean

 

[smokeysevin]

Supercharger Setup is a work in progress but here is how I am planning to adapt to the larger early model cable throttle body setup. It is just a dry fit for now but the gist of it is the flanges are 3/8" thick aluminum connected to a 3.5" OD tight radius cast aluminum bend. I counterbored the flange slightly so the tube would index on the flange. I am going to weld these in place once I get the position verified on the truck sometime in the next week or so.

Sean

 

[smokeysevin]

Fuel system part 1

I made a new fuel pump sending unit for the Bosch 450 fuel pump, new oem toyota fuel level sending unit, and the bms fuel bulkhead and got it in the tank. It makes pressure on my test loop and I should be able to get the relay setup wired later this week.

Its all 11 gauge 316ss. I only had to grind my tungsten 4 times during the assembly which is a record low for me.

The stock tundra return line is 1/4" (probably 6mm) not 5/16th like I thought.

I am planning on leaving the stock fuel pump wiring and sending unit wiring in place so it will accept a stock sending unit if I need it in an emergency. The new high power wiring and relay will go in parallel to the new connector.

Sean

 

[smokeysevin]

Injector adapters

The elate manifold I am using is setup to run stock Denso style Toyota injectors and a lot of people have reported that running the stock injectors with a rising rate fuel pressure regulator is adequate to run these chargers and motors with ~5psi. Since I am planning to run e85 I planned to run a much bigger injector. The MAP ecu I will be using to control the additional fuel and pull timing recommends going no larger than 2X the stock injector size. The pink Toyota injectors I had on the truck are 275cc and stock for my gen 2uz are 250cc. I could have gotten some flow tested and adjusted 550cc denso injectors on ebay from cyprus of all places but I opted to get some new Bosch 550cc injectors instead.

This meant that the stock type face seals would no longer work so I picked up some 0.6875" OD aluminum rod, drilled to 0.531", then used a 13.5mm reamer to finish off the bore. I cut them to ~0.54" Lenghts and then sanded the OD down to 0.6825". I pressed the new adapters into the existing ports with some loctite green retaining compound for sealing and stiction before hitting the tops with a zero flute chamfer bit.


Sean

Unmodified manifold ports

Adapter body and bore

Adapter OD after hitting it with a 36 grit belt on the belt sander

Glued and pressed in

Injector position relative to the port exit, it could be better but I don't expect issues from it

Injector position on the manifold, I could have made the adapters shorter and sunk the injector body into the port a little more but not a significant amount, the body of the injector has some little "keys" on it that foul on the body of the manifold if it sits further in.

 

[smokeysevin]

Battery mount/relay/circuit breaker holder fab

I needed somewhere to put the new relay box for the fuel pump, intercooler pump, and aux fans so I made a pseudo battery box to replace the stock toyota battery tray. It indexes in the stock locating holes and mounts my sealed relay box and the 5 push button circuit breakers that will protect the 3 new circuits plus my flex fuel sensor and wideband.

Sean

 

[aztoyman]

Nice work. Looks like a fun build. I'll be following along.

 

[smokeysevin]

IAT sensor

With boost and a charge cooler comes the need to watch IATs a little more closely. From the factory, the IAT sensor is in the maf tube, since the stock engine doesnt really have much that can change the air temp other than heat soaking the manifold, the difference in air temp from sensor to cylinder remains relatively consistent. With the sc and intercooler, the intercooler water temp, engine speed, boost, running time, vehicle speed all come into play to make the difference in iat different than stock.

To keep a better eye on it, I opted to install a RIFE fast acting IAT sensor in the manifold. It lives in the valley of the motor but the element itself protrudes into the air stream of the motor so it should be reasonably accurate for what is going on inside the engine, especially if it is running. Clearance is tight but it bolted up fine. The sensor uses a gm style iat plug and is 1/8npt.

Sean

 

[smokeysevin]

Blower is back on and the throttle body clears. I fabbed up a throttle cable mount that I am going to redo and pressure tested the coolant system, no leaks.

I also started playing with the electrical extensions for the tps and throttle body motor and looked at intake routing.

Sean

 

[smokeysevin]

Fuel filter and flex fuel sensor install

I stole the stock fuel pump bulkhead fitting out of the sending unit and adapted it to my new harness so I could plug into the stock harness for the fuel level sending unit without cutting/splicing.

The flex fuel sensor and fuel filter were mounted to a plate and the plate was mounted to the stock crossmember. I had intended to use the stock tank connection on the send side and install the new filter inline but toyota uses a weird non-standard quick connect on the sending unit connection so I opted to instead remove the first half of the stock line and use an lines from the tank to the second half of the stock sending line.

Sean

 

[smokeysevin]

Vacuum/boost Block, Fuel Pressure Regulator Mount, Throttle fitup.

The rear portion of the block is boost referenced for the map sensor, fpr, and boost gauge if needed. The front half is vac referenced for the bypass valve and charcoal evap canister.

I changed the orientation of the front crossover line for the manifold so it goes behind the snout now but this is the gist of it.

Sean

 

[Wadepat2]

Great work

 

[bbslider001]

Super nice work! Don't forget about that P/S reservoir. They will crack and leak out all of your fluid. Ask me how I know LOL

 

[smokeysevin]

I made a washer fluid reservoir/power steering reservoir holder, an intercooler reservoir holder, and intercooler pump bracker.

I need to trim the power steering lines a bit and get a real 90 for the intercooler res to pump line. The intercooler res could have been done better but I didn't want to remake it so I scabbed on some scrap. You can't see it when it is installed so I don't really care too much. The ps res is on my list, as are the crappy lines I have on it now. Pretty sure mine has leaked already.

I wanted to mount the intercooler pump lower to get more head into the pump suction side but I was worried it is less than waterproof so I stuck it where it is. Hopefully it won't cavitate too much.

Plenty of room for a proper intake setup once I figure out how I want to do it.

Hopefully I can finish up the hard fab today and get onto the wiring and pressure testing. I'm ready to be done with this build and be able to drive my truck again.

Sean

 

[smokeysevin]

Intercooler bracket fab.

Still have to make the straps to hold the cooler and trim the grille on the upper drovers side corner but the hard part is done. Plumbing is next.

Sean

 

[smokeysevin]

Hood latch, intercooler straps, and transmission cooler pre-install

I spent yesterday evening making sure the hood would close after some genious threw a giant intercooler heat exchanger in front of the radiator.

The hood latch fouled on the top of the intercooler, I had originally trimmed just the edge down but the hood was not closing properly so I had to shorten it by about 3/8". I then added a little tab to the latch so I could actually unlatch the hood. All done, its easier than stock imo.

While I was working on that, I cut the straps out to complete the intercooler hx mount. These just go across the front of the hx to keep it in place and keep it from sliding towards the passengers side. Overall, they came out decent.

I did have to cut/grind about an inch or so off the grille upper corner so the hood would actually be able to close all the way. A quick zip with an oscillating multitool and some die grinder butchery got it to close.

Last up, I built half of the new transmission cooler mount. This bolts in via 2 existing holes in the frame on the top of the passengers side frame rail. The bottom mount will require some drilling but as you can see, she ain't pristine. Eventually the frame will get replaced or fabbed from scratch but thats a problem for future Sean. This cooler will get 2 or 3 fans and a filter on the inlet. I am also planning to run a temp sensor either on the pan (I don't really want to drop it and weld it but that may be the best option) or on the send line directly behind the stock sensor on the feed to the new filter (nice and easy install) I will also be adding an exhaust heat shield and some firesleeve for the lines even though the fans should blow towards the exhaust.

Yes, the wires and air line are getting re-bundled and secured before the cooler gets bolted on for good...

Sean

 

[joseywales]

Your truck and workmanship are awesome! If I could offer a bit of constructive criticism? Your posts are painfully detailed. For instance in the last one, it took me a minute to figure out why there were two photos of your fingers coming through the grill. I want to read your whole thread, but there is SO much infinite detail it is a bit like a shop manual. It will be invaluable to someone looking to copy your modifications exactly, but it’s hard for a casual read. Maybe there is a happy medium for tech info and eye candy? Like I said, I love your truck, and appreciate the amazing quality of your work! Can’t wait to see where you go next!

 

[smokeysevin]

Your truck and workmanship are awesome! If I could offer a bit of constructive criticism? Your posts are painfully detailed. For instance in the last one, it took me a minute to figure out why there were two photos of your fingers coming through the grill. I want to read your whole thread, but there is SO much infinite detail it is a bit like a shop manual. It will be invaluable to someone looking to copy your modifications exactly, but it’s hard for a casual read. Maybe there is a happy medium for tech info and eye candy? Like I said, I love your truck, and appreciate the amazing quality of your work! Can’t wait to see where you go next!

Feedback is always welcome.

I usually try to upload the pictures and a basic overview then go back and edit the post later to make it flow a little better but I have not really had time to do that lately since kid 1 is 2 and a half and kid 2 is arriving in January, this "quick supercharger install" has turned into a late night thrash fest with no sign of slowing down.

Since mud doesnt't support tapatalk and doing batch image uploads direct from mobile is annoying, I have been dumping posts on expo and copying the bb code over so all the picture show up. That works fine but it means I am largely typing these posts up on mobile and then not making them pretty afterwards.

Sean

 

[joseywales]

I’m over on ExPo too (been on both for close to 20 years). Your sharing of knowledge is appreciated, and I understand the time constraints can be a challenge!

Happy Holidays to you Sean!

 

[smokeysevin]

Had to pull the blower back off again, I noticed it wasn't sitting flush on the gaskets and found that no matter what fitting I tried on the passengers side under manifold port, they all fouled on the water tube. So I plugged both ports and drilled two new 1/8npt ports on the drivers side of the manifold just before/above the intake ports, one for boost/map and the other for my IAT sensor. Its not an ideal location for either but at least the manifold fits.

I also finally found the pcv fitting for the stock sai port in the range rover tvs1900 blower inlet. Even better, its available as a 90. Its a dorman 15mm elbow. Pn 800-033.

Catch cans, trans cooler, and intercooler tubes are next.

Sean

 

[Wadepat2]

Looks great