Builds Project ToyLET (PICS)

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valkyrie610 said:
Good work so far, but I have to question the tabs you are using for the crossmember... seems a little flimsy to me?

Wouldn't thicker, gusseted tabs be a little more secure?
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My original plan was to cut out triangles to mount on the outer and innner edges of the tabs to act as a ramp and to provide support. I don't like how low the cross member sits especially because of all the work I did to try and keep everything above the frame rails. Right now the plan is to get a clocking ring for the 205 and get the front output shaft up out of the way, then mount the cross member inside the frame.

We just sold our house so the tabs will be good enough for me to get it onto and off of the trailer to get it to the new house to finish it. I would never wheel it like that.
 
4alarm said:
Thanks!

I hope to progress a bit faster now that I have my motivation back. Stay tuned!:D
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congrats dude .. I never try to bolt all drivetrain bolted it's really heavy !
 
Tapage said:
congrats dude .. I never try to bolt all drivetrain bolted it's really heavy !
Click to expand...

I dropped it that way. The first attempt to reassemble it I tried with all the components bolted up. In the end I dropped the t-case and just bolted up the tranny/bell housing, then added the t-case later.
 
I got the Chevy/Toyota adapter made for the master cylinder (MC) and brake booster (BB). I layed a piece of cardboard on the ground and placed the Toyota BB on top of it (MC side down). I pushed on the brake rod to make an indentation on the cardboard of the center of BB and the 4 mounting bolts (anyone know what size bolts those are?). That gave me a perfect template for drilling my holes. I started with a 3"X5 1/4" scrap piece of 1/2" plate, and transferred my template over to it. I drilled out the holes for the BB with a 3/8" bit. 3/8" is a little big, but the next size down in my kit was 5/16" and that was a perfect fit (made it tight and therefore hard to remove).

I drilled out the center with a 1 7/8" hole saw. Turned out I needed it to be 1 15/16" so I had to go larger with a 2" hole saw. It's a little loose fitting, but doesn't have to be exact. With the MC mocked up to the adapter plate, I marked the location of the mounting holes. I again drilled those out with a 3/8" bit. Then I flipped the plate over and counter sunk the hole with a 3/4" bit so my tapered flat head bolts would be flush with the BB. I snugged the bolts to the bracket and tack welded the bolts in place. I figured this would keep them from spinning in the adapter when I go to install the MC. After tacking them, I ground them smooth so the adapter would fit flush with the BB. After that all you have to do is bolt the adapter plate to the BB, and then bolt the MC to the Adapter plate. I need to find the correct nuts for the BB studs. They are 5/16" but both 5/16-24 and 5/16-13 didn't fit. I'm guessing I need metric nuts. Anyways, I'll get the rib cut off my firewall, get the old MC out of the way, and bolt up the new assembly.

3"X5 1/4" plate (FREEBIE):
brakes_008.sized.jpg


Indentions made in the cardboard:
brakes_009.sized.jpg


Template transferred over to the 1/2" plate:
brakes_010.sized.jpg
 
Thanks!

Last night I got the rib cut out between the brake master cylinder and the clutch MC. I had to enlarge the center hole for the brake MC to ~2" so the mini-truck booster would fit. I successfully completed that after a lot of time with the Dremel. Then I got sloppy:doh: I "half assed" marking the mounting holes for the brake booster and drilled the holes in the wrong location. I tried to fix it by wallowing out the holes to try and make it fit. Looks like I'll be doing some body work tonigt to try and patch the holes. This time I'll make a template to ensure proper location. One step forward 3 steps back.:crybaby:
 
I drilled out the mounting holes and welded in some washers to fill the holes. Then ground it smooth so I could start over. This time I did it right with a template made from cardboard. After drilling my new mounting holes for the brake booster I found that I had to do a little more work with the Dremel to make the booster fit in the center hole for the brake MC. The top right mounting hole for the booster interferes with the bracing for the pedal assembly. I tried to cut it out as best as I could but I'll need to get access to the plasma or torch to cut out a small section so I can get the nut on there. For now it holds with 3 bolts. I'll get the forth done before I drive it.

Holes filled:
brakes_028.sized.jpg


Booster and adapter installed:
brakes_030.sized.jpg


Left side (inside the cab) showing the mounting holes. I'll need to cut out the pedal assembly around the top hole to fit a nut on that bolt:
brakes_033.sized.jpg


Chevy MC bolted up:
brakes_036.sized.jpg


Completed (almost):
brakes_035.sized.jpg
 
One quick and I hope not obvious question.
How are you determining the push rod length between the MC and the booster?

If its to long the brakes will drag.

Does that rod adjust?

Thanks

Oh yeah, nice build!
 
really nice work, very good fabrication skills, cant wait to see the finished project.
 
The mini-truck booster and the factory MC push rods appear to be about the same length. They are adjustable however. Until I get the rest of the system plumbed (i have to order all the fittings) I won't be able to tell for sure. Currently there is slight play in the pedal then it engages. It feels good.
 
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