Topic: Project Get Nasty 1982 SR5

[GNasty 82]

OK, figured I'd better go ahead and start a project thread, if for no other reason than the keep myself motivated and organized.

The base rig is a 1982 Toyota SR5 pickup.  I bought it for $800 from a guy on craigslist.  I went and looked at the truck and would have been immediately put off by the amount of rust in the rear frame  if it wasn't for the price.  The truck was obviously from somewhere up north.  The bed/tailgate was rusted badly.  The rear portion of the frame had rusted through and been patched (badly) on one side.  The upside was that the entire drivetrain looked really good and the motor started right up and purred like a kitten.  Granted, there was an issue with the carb not wanting to let it idle properly, nothing a carb rebuild couldn't fix.  The guy said I could have everything that was in the bed of the truck as well, and low-and-behold, laying in the bed was extra Toyota gear driven tcase  .  Long story made short, I gave the man $800 bucks and drove home a great project truck.

[79coyotefrg]

looks good, where you from??

[GNasty 82 [OP]]

Well, of course I had to to wheeling with it to begin with to get a general idea baseline performance.  Well as expected, the rear frame broke.  I actually got hung up and ripped one of the rear spring hangers right out of the frame.  Did some trail patching w/o a welder and drove home.

Now the project really begins.  So now I've got a truck with a busted rear frame.  Simple solution, cut off the rear frame and start from scratch.

I began by modeling everything up in Google SketchUp (thanks for the free 3D modeling suite Google  )  I knew that I wanted to go ahead and integrate a roll bar/headache rack.  (33" tires are modeled up for reference).  This model also served the purpose of helping me figure how much of what steel to buy.

To build a new rear frame and attach it to the existing front frame, I came up with what I thought was an ingenious solution.  I noticed that the existing Toyota frame was just 2 pieces of c-channel welder together to form a box frame.  I also noticed that the box had nearly a 2"x4" inside dimensions.  So my solution was use some 1/8" wall 2"x4" rectangular tubing for the new frame.  As it turns out, I was able to get the 2"x4" tubing to slide inside the existing frame.  So I made some pieces that ran inside the frame all the way up to where the frame bends inward (about 4" before the front shackle mounts).  I proceeded then to follow the model making minor corrections when necessary.

[GNasty 82 [OP]]

I am in Huntsville, Al.  I bought the truck from a guy who buy/sells/trades vehicles on craigslist in Tennessee.

[hilux-1983]

 8)

[GNasty 82 [OP]]

Once the frame was to the correct length, I welded on new spring hangers and began to mock up the rear axle.  I actually took a different approach to mounting the shackles.  I decided that instead of welding on shackle mounts, I would use some front shack tubes meant for a SAS swap.  I figured that would be a stronger mount than the normal ones, especially with my mediocre welding skills.  I did have the problem of the DOM tubing being too long for the rear shackles, but that's nothing major to correct.

Being that I consider my welding to mediocre (at best) and my welding machine is a PoS, and the fact that my new frame has hard angles in it rather than smooth curves like the stock frame, I decide some gussets made from 1/4" plate in the corners would be a nice strength adder.

I then added crossmembers and welded on shock mounts.  I also added another piece of 1/4" plate to the inside of the corner where the shock crossmember is for even more strength.

For bonus redneck points, I've included a picture where I threw a 5gal gas jug on the back so I could test drive it around the yard .  I got little carried away and actually did some minor trenching of my own back yard, but the frame held so time for 

[thegoofster21]

looks good

[GNasty 82 [OP]]

Next step was to build a bed since the stock bed was rusted to badly.  The obvious answer was a flatbed.  It was also about this time that I decided that I wanted to go propane since I had already had lots of trouble with the stock carb and wheelin.  So I proceeded to draw all this up in 3D as well.  (Note: Props must be given to Cary at gotpropane.com, he was extremely helpful.)

Unfortunately, I forgot to take some pictures of the rest of the build of the bed to the point at which it is now (still needs rails and a deck plate and a better lighting solution), but here is a couple of pics of what it looks like now.  Yes, I have been wheelin with it and it work great.  The only problem I have is that the tires rub the underside of the bed frame and the side of the frame a little when under high articulation, but that will be fixed when I order Marlin's Trail-Flex 4" kit.

[GNasty 82 [OP]]

I was about to build the rails and buy the deckplate, but then Marlin and friends went and had to put the MC07 on sale, so now I have a MC07 and 4.70 gears to go with my extra Tcase, but those are going to have to wait till after the new year to be installed.  Gotta save up for driveshaft mods and a twin stick shifter.  One of these days, I'll get around to ordering my 5.29 front and rear gears along with lockers.

I'll try to take pics along the way and put them here as I do.

[germ85]

Your truck looks good. When I get mine going we need to get hook up a ride. I'm in albertville al.

[SloCrawler]

Hey you copy my flatbed. lol

[THK Matt]

[rgacord]

did you draw this up using "google scetch up 3D

[santa cruz crawler]

dude awsome frame rails! your shackel deal is sweet also 

[Braswell91]

Sick lil project man! I emailed you askin for some info. Anyone know of a yota for sale in the north alabama area for cheap?

[MRHilux87]

Nice backyard fab work!  looks straight and solid.  Any flex in the rear frame or does is seem like stock?