91 xtra cab build

[jarboarder1]

Well I figured it was about time to post up the build I have started.
the goal:  A very functional wheeler while being a reliable daily driver.
the truck: 1991 extra cab 3.0 V-6
Build at this time
      SAS the front
      Chevy swap the rear
      Lock the rear
      Some armor

+Parts list
-Front spring hanger kit Trail-Gear
-High Steer Trail-Gear  
-Steering Box mount Trail-Gear  
-U-Bolt flip kit Trail-Gear
-Shock Hoops 12" Trail-Gear
-Break Lines Trail-Gear
- 78" Sliders Trail-Gear
-Chevy Spring kit Sky Man.
-Toyota Rear Shock Hoop Kit Sky Man.  
-Toyota Axle widening kit Sky Man.
-FJ 40 rotors
-Front springs  Datin Fab/ trail gear
-Chevy springs 63"
plus other stuf i didnt write down


In the near future
   Duals
   Re-gear
   30 sline longs
   Lock the front
   Front and rear bumpers
   Half doors


So here is what we have to start with


jarboarder1

[bigarms23]

thats a nice truck to start with have fun buiding

[GJToyotabug]

hey when you trash all the IFS and rear springs and all the shocks let me know I need all of the shocks cuz mine are beond toast, the leafs, torsion bars, and the CV joints. please tell me I can pick them up. I also live in colorado.

[jarboarder1]

hey when you trash all the IFS and rear springs and all the shocks let me know I need all of the shocks cuz mine are beond toast, the leafs, torsion bars, and the CV joints. please tell me I can pick them up. I also live in colorado.

Someone already has dibs on the rear leafs, but the shocks and ifs stuff is up for grabs. The shocks are after market Rancho's, so im looking to get a little something for them.

[jarboarder1]

This is the axle we built in between my house in Boulder and the shop I do work at on campus.
I am an Engineering student at the University of Colorado so working on the axle in one of the shops was a nice little project here at school.

The first axle i got was bent  ( A great way to start off my first build) but luckily was able to find someone who wanted it for close to what I bought it for
stuck birf on the old bent axle



So once I got rid of the bent axle I picked up this one and cleaned it up 


the axle being worked on in the CU welding shop
Armored this thing up with Sky's truss and diff armor and used marlins gussets.




Here is my buddy Mat who is walking me through the build 


a couple more pics of rebuilding the axle


Got my little bro doing some of the shity work   its ok this truck is going to end up being his


also decided to go with Sky's widening kit instead of wheel spacers. I like the piece of mind since its a daily driver.



so here is the axle waiting to be put in

[Matty]

truck looks great so far.  its been a fun project to work on.  cant wait to start my new one.

where are the rest of the pics?

[jarboarder1]

truck looks great so far.  its been a fun project to work on.  cant wait to start my new one.

where are the rest of the pics?

There are more pics coming. just give me a little time.

[Toymin8r]

You spent all that time on that axle housing you should have spent the extra 10 minuts to spray some paint on those knuckles.   Would't have made for a better poser pic. 

Nice work otherwise   

[Doof]

looks good so far.... keep it up

[Jud]

Looks fun. Good luck!

[jarboarder1]

Since My garage isn't big enough to work on a truck I have to do this build at my parents house which is a real pain in the ass because I have classes 5 days a week and a lot of other stuff going on as well. My parents house is about 45 minutes away which is a ways to drive just to get to my truck. So Saturdays are the only days that I get any work done on this build.  Cant wait for school to get out for the summer.

Anyways we started of with the rear suspension first. Went with some Chevy springs.


cut off the overloads i didn't like them there and Im not going to be carrying heavy loads so i didn't see a point in keeping them.

The bushings were shot. Had one hell of a time getting them out. Ended up drilling and burning them out
Even got the old man helping with them


Replaced the old ones with some energy suspension bushing



For the rear I went with Sky manufacturings Chevy swap kit.

Here is the rear after we pulled all the suspension out.


front hanger being welded on




Here Is the welder I'm using. Its a Hobart 187. I havn't had it for long but I love it   


trying to test out the new rear suspension.





It seemed to work well but we didn't have anywhere to really test it out.

So we turned it around so we could start working on the front.

and here is how its sitting now.

[94MtnYote]

 hey nice truck, looking forward to more progress and pics!
umm, I thought the overloads keep the leaves from flexing out too much?

[Jud]

You should have left the rear part of the overloads on because they help out alot with axle wrap.

Looks good tho!

[jarboarder1]

hey nice truck, looking forward to more progress and pics!
umm, I thought the overloads keep the leaves from flexing out too much?

Thats true they do But I'm not very worried about going negative with them. If I mess them up I can get another pair for $50 bucks, and if they flaten out It just means they will flex even better.

You should have left the rear part of the overloads on because they help out alot with axle wrap.

Looks good tho!

thats a good point didnt really think about that.
oh well its too late now

[94MtnYote]

 yeah pick n' pull should have overloads for next to nothing if you need em'. 

[GJToyotabug]

ok pm me when you have all of the shocks off and tell me how much you want

[DTB]

ok pm me when you have all of the shocks off and tell me how much you want

You remind me of my friend, Eazy.....he's always right there helping me pull old parts off my truck to put on his! 

[jarboarder1]

Alright so over the weekend I got the front torched out.

This is the last weekend to work on it before finals. Now I have to wait until may 7th to work on it again. My brother should be working on grinding the frame smooth so that we can get straight to work after I'm done with the semester.

Any ways here are the picks

Last pic of the ifs   



Starting to torch away, there is no turning back now



And it finally it hit the ground



The famous torched ifs.  Every build needs this shot 



The frame waiting to be ground down


And here is how it sits until I'm done with this semester



That was a lot of fun and I can't wait to through the axle under it.

[DTB]

And here is how it sits until I'm done with this semester

That was a lot of fun and I can't wait to through the axle under it.

Is English included in part of your curriculum?


Just kidding 

Looks nice! Love the obligatory IFS shot hehehehe

[jarboarder1]

Is English included in part of your curriculum?

Actually no. Im an engineer they only care if i can add.   

[ajordan1975]

Actually no. Im an engineer they only care if i can add.  

even then all you need is a calculator.

[Phazertwo]

We should wheel! I am in Lafayette.

[Matty]

 nice

[jarboarder1]

We should wheel! I am in Lafayette.

yea definitely. All my attention is on this build right now, but I cant wait to go wheeling.

[jarboarder1]

Damn it all! All I want to do is work on this thing, but finals are really cramping my style. 
Only 5 more days and 3 finals to go then Im home free

[jarboarder1]

Alright so school is finally done for the summer!
So once i got home I went straight to work, but its been slow since Im doing most of this by myself.
Anyways here are some pics

Here is the front hanger with a 3/16 spacer welded to it.


Hanging the springs


Here is the shackle. It is sitting right around 12-13 degrees back. that should work just about perfect.


Here It is with the axle strapped on. Just starting to mess around with the steering.


Hopefully tomorrow I get all the steering stuf figured out and I can go test it out a little.

[DTB]

very nice! looks almost exactly like my axle! good job

[jarboarder1]

Alright so I didn't get as much as I wanted done today but its rolling. I need to finish up the steering and then clean everything up and then do shocks.

I have been waiting so long to get to this spot. I love seeing it with the solid axle under it.

[Jud]

Looks good man! Paint those knucles tho! lol

[jarboarder1]

Alright so I got the steering moved forward, and got it rolling. Drove it around the driveway and up the road a little. It works. 
I need to mess with the steering a little bit more to fine tune it, but everything seems to be good.

I used the trail-gear steering box mount and moved it forward almost 2 inches.


I thought this was kinda funny. This was stamped on the front of the steering box.  toyoDa   


Hears the steering box all mounted up. The tie rod and drag link are a little better than parallel, so it looks like everything should clear.


Had to extent the steering shaft 1 1/8 inch. I used quarter inch pipe, welded it up good and its working great.


And here it is after we tied up a few of the loose ends.   


I had to get one tire up higher than the other, so i drove it up on a small ramp that was hanging around. Man look at that flex