Lightweight Daily Driver Build "The Satchel" (1 Viewer)

[Crab Sack]

I wanted to start out this build with a big thank you to all of you who have posted their progress on their builds and I am hoping to give back a little bit of that as well with this thread.
I am sure that I have seen and read every build thread in the 200 series forum and there were 2 that stood out for what I wanted to accomplish @Mineral and @linuxgod. I wanted a light weight daily driver that would suit my occasional off road needs, tow a boat and a travel trailer, and fit into a parking garage.
The first stage to upgrade the 200 was to install the factory spring spacer and 275/70/18 BFG ATK02s.
This was fine and all but I did not like the way the factory suspension felt when loaded down and did not like the skinny tire look; Bowling ball riding on razor blades.

After much deliberation I had decided to install a mild 2" OME light weight lift with the following pieces:

1x 2702 Front Springs
1x 2721 Rear Progressive Rate Springs
2x 91005 Shocks
2x 61029 Shocks
2x OME80PR10 10mm Rear Spring Spacer
1x OME661 Rear shock rock guards
1x SPC 25465 Upper Control Arms set at 1 degree caster

Just to clarify I am no longer using the OEM front spring spacer with this setup.

On order are Icon Six Speed Wheels in Titanium with Nitto Ridge Grappler 285/75/17 Load range E tires.

The install went well with the help of a friend and the alignment came out perfectly. One degree of positive setting on the SPC easily got me to around 4 degrees of caster. I backed it down to about 3.7 degrees of positive caster overall.
Right now the 200 has just minor bit of rake to it which I like.
Measurements from the center of the wheel to fender are:

Front 22.5 inches
Rear 23.0 inches

The factory 1/2" lean to the left is gone and it sits perfectly level side to side.
I can honestly tell you that the ride is much firmer in a good way and it feels confident rolling down the highway.
Here are a few pics of the before, during and after.
Before with factory spring spacer, and 275/70/18s

During the lift:

Waiting for the Icon wheels to show up:

 

[Markuson]

Nice work, and great idea on deliberately posting s build for your unique, lighter goals. Tons of build threads involve massive stuff, but not many for lighter builds as the main focus. Looks like you’re in good shape so far!

 

[Tommy Dwyer]

I wanted to start out this build with a big thank you to all of you who have posted their progress on their builds and I am hoping to give back a little bit of that as well with this thread.
I am sure that I have seen and read every build thread in the 200 series forum and there were 2 that stood out for what I wanted to accomplish @Mineral and @linuxgod. I wanted a light weight daily driver that would suit my occasional off road needs, tow a boat and a travel trailer, and fit into a parking garage.
The first stage to upgrade the 200 was to install the factory spring spacer and 275/70/18 BFG ATK02s.
This was fine and all but I did not like the way the factory suspension felt when loaded down and did not like the skinny tire look; Bowling ball riding on razor blades.

After much deliberation I had decided to install a mild 2" OME light weight lift with the following pieces:

1x 2702 Front Springs
1x 2721 Rear Progressive Rate Springs
2x 91005 Shocks
2x 61029 Shocks
2x OME80PR10 10mm Rear Spring Spacer
1x OME661 Rear shock rock guards
1x SPC 25465 Upper Control Arms set at 1 degree caster

On order are Icon Six Speed Wheels in Titanium with Nitto Ridge Grappler 285/75/17 Load range E tires.

The install went well with the help of a friend and the alignment came out perfectly. One degree of positive setting on the SPC easily got me to around 4 degrees of caster. I backed it down to about 3.7 degrees of positive caster overall.
Right now the 200 has just minor bit of rake to it which I like.
Measurements from the center of the wheel to fender are:

Front 22.5 inches
Rear 23.0 inches

The factory 1/2" lean to the left is gone and it sits perfectly level side to side.
I can honestly tell you that the ride is much firmer in a good way and it feels confident rolling down the highway.
Here are a few pics of the before, during and after.
Before with factory spring spacer, and 275/70/18s
View attachment 1884385

During the lift:

View attachment 1884386
Waiting for the Icon wheels to show up:

View attachment 1884388 View attachment 1884389

Looks great! Quick question: you installed rear spring spacers, is that because you kept the OEM front spacers when you installed the lift?

 

[Crab Sack]

Looks great! Quick question: you installed rear spring spacers, is that because you kept the OEM front spacers when you installed the lift?

Good question and I am no longer using the OEM front spring spacer with the OME lift.
Most people who sell OME are pairing the 2702 front springs with the 2722 rear springs, however I wanted the progressive rate spring for towing as well as the comfort factor when not towing. There are quite a few posts on here that say the 2722 rear spring is a much harsher ride on an unloaded light vehicle. So the reason for the rear spring spacer was to help give the ride just a slight amount of rake to make up for the lack of height a 2722 rear spring would give. If you wanted a perfectly level ride I would prob only install a 5mm rear spring spacer.

To quote @Taco2Cruiser on a different thread:

Front stock spring rate is 500 lbf/in
OME springs rates are:
2700: 625 lbf/in, 420 mm free height, 18mm bar diameter (1" lift, stock bumper)
2701: 720 lbf/in, 425 mm free height, 19mm bar diameter (1" lift, steel bumper and winch)
2702: 625 lbf/in, 430 mm free height, 18.5mm bar diameter (2" lift, stock bumper)
2703: 720 lbf/in, 435 mm free height, 19mm bar diameter (2" lift, steel bumper and winch)

For comparison, BP-51 front spring is 750 lbf/in, preloading takes it much higher, but also the internal charge of a BP-51 is 290psi! To give you an idea, when I build prerunners I almost never go past 255 psi.

It really depend how much weight you are going to carry, and how high you want your truck to sit. All the rear springs have different coil thicknesses (which is why 2721 and 2722 are not as easily comparable as just knowing the lbf/in of them) 2723 is actually the tallest springs, with 2724 and 2725 being shorter.

In fact, lets just do this:

Stock rear spring: 170 lbf/in
OME rear springs:
2720: 270/350 lbf/in, 420mm & 410mm free height, 18.5mm bar diameter (OME says drops rear .75", I don't feel it does)
2721: 270/350 lbf/in, 440mm & 430mm free height, 18.5mm bar diameter (more lift than OME states of .75" lift)
2722: 275 lbf/in, 440mm & 430 mm free height, 19mm bar diameter (.5mm thicker bar, would equal a constant 220 lbs load over 2721)
2723: 340 lbf/in, 450mm & 440mm free height, 20mm bar diameter (constant 440 lbs load)
2724: 400 lbf/in, 445mm & 435mm free height, 21mm bar diameter (constant 880 lbs load)
2725: 440 lbf/in, 445mm & 435mm free height, 22mm bar diameter (constant 1300 lbs load)

 

[TeCKis300]

I applaud the lightweight focus and it's definitely something worthwhile to focus on. My build was in the spirit of keeping things lightweight, for better dynamic performance. Like you, also to preserve towing performance.

It's definitely hard at times, as things just start adding up. Every pound saved here or there is still remaining capacity for other tasks. Jeeps have been onto this for awhile (because of their poor payloads), but even the heavier HD trucks out there have aluminum and lighter weight options for armor, etc.

Ultimately, it still comes down to what one wants to do. Rock crawling/bumping, still requires heavier armor, so it's a trade those individuals are willing to make.

 

[Itsky]

Great build @Crab Sack ! I’m going the same direction with my 2013. I value your insight on the suspension, thanks for the details.

 

[Tommy Dwyer]

Ditto, thanks for your thoughts and insight.

 

[fireball]

Thanks for sharing! The best builds are the ones like yours that start off with a clear focus and specific goals which then can guide all build decisions.

What’s the tongue weight on your TT and boat trailer? Think airbags will be in your future?


Will look forward to following along!

 

[Whiskerz]

Have you considered pulling out the sound deadener ? I was noticing when I removed the 3rd row seats the rear has a mat under the carpet that looks like it weighs 40 pounds.

 

[Ninja Cruiser100]

Nicely done and well thought out!

 

[ForrestGrump]

That rug really ties the room together.
Nice rig, lift looks good!

 

[CGP]

I'll be following this build as it is very similar to my goals. Mostly on road, towing motorcycle trailer, camping and possible a bit of dirt roads out west. Light is right!(mpg wise that is).

 

[Crab Sack]

My boat trailer tongue weight is only about 400lbs so that was never really an issue when towing. The travel trailer weighs in around 475 tongue weight and 4900 dry so in reality loaded down I’m guessing in the 800 lbs range by the time I add 2 golf cart batteries, 60 pounds of propane and equalizer hitch. I have weighed the trailer loaded at 5600lbs. I always tow with a Tundra and have no complaints there but I would like to have the cruiser and the camper together for other trips. I never felt confident in the stock suspension on the 200 to safely tow the TT. All of the trailers are winterized so it will be a few months before I can test it out to see if I need to add airbags and follow up with my results.

On a side note the 275/70/18s rub more on the sway bar with the lift than before. If I were to keep these wheels I would definitely need to add wheel spacers.

I am still semi-patiently waiting for Icon to ship the six speed wheels.

Glad you like the magic carpet. That rug has saved my knees and back from cold concrete when working on all my builds. I highly recommend it. The fancier the better. There is also another one on the other side as well.

 

[Crab Sack]

Just got my jack adapter from @LandCruiserPhil. Thanks for the mints.

If you have ever had to use the stock jack you would understand how useful this little adapter is. For $36 and helping out a mud member. Well worth the price.

 

[Crab Sack]

The Icon Six Speed wheels in Titanium Color arrived today as well as the 285/75/17 Load Range E Nitto Ridge Grapplers. I had to do a bit of manipulation on the front wheel well liners to clear the sweep of the tires. I am hitting a bit on the KDSS bar on the front left tire during a hard right turn. I will try to drop caster back by 1/2 degree on the LF side to try to gain clearance between the tire and KDSS bar. Other than that I think the wheel to lift proportion is perfect and I am happy with the results. One of the other main goals on this lift was to keep it under 6'8" in total height to fit into the work parking garage. My overall height came in at 6'7.25" .

 

[tarheel40]

@Crab Sack - Your build is looking great so far, amazing how much the new wheel/tire combo changed the look of the cruiser! Would love to hear your feedback once you get some miles on this setup of the switch from 275 KO2’s to the 34” Ridge Grapplers. I’ve currently got 275 KO2’s on my 2016 and installed a TD suspension last month, trying to convince myself that the tires don’t look way too small now but I’m not doing a good job haha.

I’m planning to keep the factory wheels but am seriously considering the move to 285/70r18 Ridge Grapplers. My biggest concerns are adverse affects on ride quality and gas mileage. Most reports say the Ridge Grapplers are smooth on the highway and very quiet, what are your thoughts compared to the KO2’s? Can you tell a big difference in acceleration and handling? The tread pattern is probably more aggressive than I need but the Ridge Grapplers seem to be the best option in the tire size I’m looking at that has very few choices.

 

[Crab Sack]

@Crab Sack - Your build is looking great so far, amazing how much the new wheel/tire combo changed the look of the cruiser! Would love to hear your feedback once you get some miles on this setup of the switch from 275 KO2’s to the 34” Ridge Grapplers. I’ve currently got 275 KO2’s on my 2016 and installed a TD suspension last month, trying to convince myself that the tires don’t look way too small now but I’m not doing a good job haha.

I’m planning to keep the factory wheels but am seriously considering the move to 285/70r18 Ridge Grapplers. My biggest concerns are adverse affects on ride quality and gas mileage. Most reports say the Ridge Grapplers are smooth on the highway and very quiet, what are your thoughts compared to the KO2’s? Can you tell a big difference in acceleration and handling? The tread pattern is probably more aggressive than I need but the Ridge Grapplers seem to be the best option in the tire size I’m looking at that has very few choices.

I would look at the Ruby Build for answers to your questions. I only have about 10 miles on the tires at this point but they are quiet and they seem softer than my K02s. Perhaps this was from going to a 17" wheel. I haven't noticed a difference in throttle response yet but it is too early to tell.

Here is a link to Ruby, I really like his build:

Builds - mcgaskins' 2016 build thread - Ruby

 

[Crab Sack]

A little bit of an update since it is starting to finally thaw out up here in the pacific northwest.

The purpose of the build was to keep the vehicle lightweight yet functional for towing so it is finally warm enough here to set up the travel trailer for towing.

Installed a Redarc Tow Pro Elite brake controller and then set up the Equalizer hitch with a new drop hitch.
Just gave the trailer a test run and couldn't be happier with the results.
I never dared to tow the trailer with the 200 with the soft stock suspension. I hated the way it drove with a full load of passengers.

The 200 tows great and stable with the OME suspension and I am glad I went with the 2721 rear springs.
Right now I don't feel that rear airbags are needed but will re-assess after the first camping trip.

 

[TeCKis300]

Great looking setup. Meaty tires and wheels look great also.

If you're ever looking for more towing stability, looks like you can bring the drop shank in towards the bumper quite a bit. It has the same functional
effect as increasing the wheelbase.

 

[fireball]

Looks great, the truck sits pretty darn level with the trailer in place. Any idea what the tongue weight is?