91 Extracab Frame Up Rebuild

Cyberman · 12-01-2007, 04:47 PM

What seemed like a somewhat easy engine rebuild has now become a frame up restore. This '91 Extracab was given to me, after the PO ran it without oil. They managed to blow 2 rods in the process. While waiting to get the money together to get a replacement block, I decided to look into taking care of some rust issues on the frame. As a result, I've found the following problems (apparently the PO didn't take very good care of this truck):

1. Blown engine, heads appear fine so far
2. Upper control arm shafts are very rusty. The driver side looks like it could snap like a pretzel.
3. Inner CV boot is in 2 pieces.
4. Front suspension is pretty rusted, looks like original shocks are on it, the top of all the shocks are rotted through.
5. Rear cab mounts are rusted, and will probably need new ones welded on.
6. Normal Rear sag.
7. Rust rot on the underside of the rocker panels, pretty much the entire length of the cab.
8. Driver floor rusted from standing water under the carpet.
9. Lower fender mount on the driver side is gone.

That's all I can think of now, I'm sure I'll probably uncover more.
I'm hoping to make this an ongoing project thread for myself, and will update it as often as I can.

Currently, the engine, tranny and driveshafts are off. The body mounts are loosened/removed with 2x4s holding up the driver side. I'll probably be pulling the truck out of the garage for the winter, so I can pull my car back in. I don't have anywhere to put the body, so it'll probably stay together until it gets warm again.

The plan in short is to remove the entire body and recondition the frame, suspension and underbody. Then will come the engine rebuild and about a dozen things in between. Before anyone suggests it, I'm not going SAS. That's a little too complicated and costly for me. I'm also not doing an engine swap, well at least not now. This is a project, and as such will be done as often as I have the time and money to do it.

Any thoughts or suggestions from those who have travelled before me are very welcome.

A picture when I picked it up

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Cyberman · 01-14-2008, 08:00 PM

I took a break from this project, cause I was getting frustrated with the weather. The truck is now back in the garage, and pretty much stripped down.

Now come more issues and concerns. First of all, the driver side of this truck appears to have seen more wet weather than the passenger side. As shown in the pictures below, there is a nice crack and a hole in the firewall, on the outside of the wheel well. The entire underside of the rocker panel needs replaced. Lastly, the frame and upper control arms have quite a bit of rust.

Everything seems like it can be repaired, except, I am by no means a welder. I am about to make a purchase at Eastwood for a frame restoration kit. I have vacation coming up in 2 weeks and was going to get to work on the frame. If anyone thinks different, please chime in. Any insights are welcome.

Cyberman · 01-19-2008, 05:03 PM

Thanks for all of your replies and input so far. I'll be on vacation starting 1/25. The frame will start to be restored then.

More pics, body off the frame:

bigtrucknwheels · 01-22-2008, 07:25 PM

cool to see someone giving one of these trucks the love it should have!

awesome! keep the pics coming, Id love to see them!

Cyberman · 01-27-2008, 08:23 PM

I got the frame rolled out, and in the other bay while the wife is away for the week. I was able to sandblast just about half of it. It appears I'll have to cut the torsion bar bolts off, they don't want to come loose. I should have up to the front suspension blasted and hopefully repainted by the end of the week.

ocdropzone · 01-27-2008, 08:58 PM

Sounds like the perfect time to SAS that thing

Frame off is the way to do...

sh0kk86 · 01-27-2008, 11:56 PM

wow, awesome work. while your at it, even though you said your no welder, got friends who can help reinforce the frame while you have the chance? mainly steering, and maybe the rear end of the frame??

por15 or some other rust preventing paint would be a good idea when your done w/ it.

keep the pics coming man, must be a fun project to work on

Cyberman · 01-28-2008, 01:33 PM

Quote:

Originally Posted by sh0kk86

wow, awesome work. while your at it, even though you said your no welder, got friends who can help reinforce the frame while you have the chance? mainly steering, and maybe the rear end of the frame??

por15 or some other rust preventing paint would be a good idea when your done w/ it.

keep the pics coming man, must be a fun project to work on

Not sure what reinforcement would be necessary, this is my first truck build.

I've already got Eastwood products sitting here to be put on after the blasting (Rust Encapsulator and Chassis Black).

I just stopped by the yard where I am getting a new 3.0. Saw a 95 Limited Runner. If things go right, I might have a 3.4 to swap in as well (w00t).

RobD · 01-28-2008, 01:40 PM

Quote:

Originally Posted by Cyberman

If things go right, I might have a 3.4 to swap in as well (w00t).

Like Nike used to say: Just do it!

Don't even bother with the 3.0 if you have a chance to 3.4 with the body off. Trust me, you'll be waaaaaaaaay ahead of the game.

Cyberman · 01-28-2008, 06:24 PM

Quote:

Originally Posted by RobD

Like Nike used to say: Just do it!

Don't even bother with the 3.0 if you have a chance to 3.4 with the body off. Trust me, you'll be waaaaaaaaay ahead of the game.

Well, I just read that it's best to get a 3.4 from a manual if I have a manual, and I'm pretty sure this was an automatic. Did Toyota really put a different crank in based on the tranny?

Cyberman · 01-30-2008, 02:59 PM

Some more pics. I think this truck needed shocks. What do you think:

Everything is off the front end, except the control arms. You'd think there would be enough leverage on the back wheels to just pick that front end up like a wheelbarrow, but no:

tortis · 01-30-2008, 03:52 PM

shocks are the least of your worries.

the 3.4 would be sweet. goood luck on that score.

Cyberman · 03-16-2008, 05:53 AM

It's been a while since I've posted here, but I've made some progress this weekend.

I finally got the frame coated in Eastwood's Rust Encapsulator and Chassis Black. It looks great. Now I have to do the same to the rest of the suspension components (front diff, rear axle, springs). It's finally starting to look like it's going to be worth while.

Rust Encapsulator

Chassis Black

SEAIRESCUE · 03-16-2008, 06:52 AM

Good job. Hope you don't burn out. Hope the wife is understanding. I suggest you find another cab. One picked over at the bone yard. If you had the option, one from a dry climate would be ideal. Rust sucks and the time you will put into fixing that rotten cab will be no more than finding a replacement and bringing it home. I have cut my share of rust out and patched. Its tough.

MY $0.02

pwd · 03-16-2008, 06:58 AM

Awesome! I wish my frame looked like that, I love seeing people remove rust!!

Cyberman · 03-16-2008, 09:27 AM

Quote:

Originally Posted by SEAIRESCUE

Good job. Hope you don't burn out. Hope the wife is understanding. I suggest you find another cab. One picked over at the bone yard. If you had the option, one from a dry climate would be ideal. Rust sucks and the time you will put into fixing that rotten cab will be no more than finding a replacement and bringing it home. I have cut my share of rust out and patched. Its tough.

MY $0.02

This project is actually my relaxation from work, so I won't burn myself out. I'd love to find a real cheap cab, but here in PA a rust free one is kinda hard to find in a yard (let alone finding a truck in the first place). I'll be patching up the cab as best as I can. I'll be getting a replacement rocker to weld in, and then probably sandwich the crack with a couple of flat pieces. I've already been through removing the cab, so replacing it later down the road won't be that bad. I'm pretty much set on putting a 3.4l in from a rolled 4Runner I found. I'm hoping to put it in with the body off. It's much easier working aroud the chassis without a big hunk of sheet metal all around it.

The frame inspired me to blast both upper control arms, the crossmember and the gas tank skid plate today.

More to come...

bigtrucknwheels · 03-16-2008, 03:36 PM

Quote:

Originally Posted by Cyberman

This project is actually my relaxation from work, so I won't burn myself out. I'd love to find a real cheap cab, but here in PA a rust free one is kinda hard to find in a yard (let alone finding a truck in the first place). I'll be patching up the cab as best as I can. I'll be getting a replacement rocker to weld in, and then probably sandwich the crack with a couple of flat pieces. I've already been through removing the cab, so replacing it later down the road won't be that bad. I'm pretty much set on putting a 3.4l in from a rolled 4Runner I found. I'm hoping to put it in with the body off. It's much easier working aroud the chassis without a big hunk of sheet metal all around it.

The frame inspired me to blast both upper control arms, the crossmember and the gas tank skid plate today.

More to come...

What part of PA are you from?

And I know what you mean, finding a truck is hard, finding one rust free is next to impossible (esp. if you're in northern PA), and finding an Xtra cab, forget about it... At least in scrap yards, there's a lot of trucks on the road down this way, but most have cancer. thats why I bought my truck, its cleaner than most Toyota Pickups I have ever laid eyes on haha.

I still am really inspired by your project, and I find this to be a project I may be doing here real soon.

keep us posted, please!

Cyberman · 03-16-2008, 06:14 PM

Quote:

Originally Posted by bigtrucknwheels

What part of PA are you from?

And I know what you mean, finding a truck is hard, finding one rust free is next to impossible (esp. if you're in northern PA), and finding an Xtra cab, forget about it... At least in scrap yards, there's a lot of trucks on the road down this way, but most have cancer. thats why I bought my truck, its cleaner than most Toyota Pickups I have ever laid eyes on haha.

I still am really inspired by your project, and I find this to be a project I may be doing here real soon.

keep us posted, please!

I'm down here in Dillsburg, but originally from up there in Danville. I was up there yesterday, and saw a pair of trucks right along 11/15 below Selinsgrove. One looked like parts for the other, but they were both standard cabs.

A friend of mine has a 94 22RE standard cab in great condition. I've borrowed it a few times to get firewood. But, nothing beats the legroom you get in the Xtra cab, especially if you're 6'1".

bigtrucknwheels · 03-16-2008, 06:23 PM

Quote:

Originally Posted by Cyberman

I'm down here in Dillsburg, but originally from up there in Danville. I was up there yesterday, and saw a pair of trucks right along 11/15 below Selinsgrove. One looked like parts for the other, but they were both standard cabs.

A friend of mine has a 94 22RE standard cab in great condition. I've borrowed it a few times to get firewood. But, nothing beats the legroom you get in the Xtra cab, especially if you're 6'1".

I know about the legroom, I'm 5'11" and to say the least, not the thinnest thing to walk this earth...

I will have to swing down 15 sometime this week and check them out. 3rd gens?

isaac338 · 03-16-2008, 06:24 PM

did you brush that paint on or spray it? looks great!

Cyberman · 03-16-2008, 06:49 PM

Quote:

Originally Posted by bigtrucknwheels

I will have to swing down 15 sometime this week and check them out. 3rd gens?

Ya, 90 or 91, both same color as mine. I can't remember exactly where on 15 they were though. I'm pretty sure it was before Liverpool.

Cyberman · 03-16-2008, 06:55 PM

Quote:

Originally Posted by isaac338

did you brush that paint on or spray it? looks great!

The bulk of the encapsulator was brushed on, then followed up with an aerosol. I used an aerosol of chassis black for the first top coat, but will follow up with a brush coat. 1 qt. of encapsulator will do the whole frame, and then some. An aerosol comes in handy though afterwards to get where youu can't with a brush.

Cyberman · 03-22-2008, 07:11 AM

Here's a few more pics. I actually put something back on the frame (w00t).

A few more pieces coated, sry for the dark pic

Before

After

shoes138 · 03-22-2008, 07:43 AM

wow awesome build!!!! hope everything works out great for ya!!
that encapsulator looks like it works great!

CoedNaked · 03-22-2008, 08:26 AM

Go and pick up some fluid film and coat your entire frame and suspension components with it. It'll protect the metal and the frame will bead water nicely.

01-14-2008, 08:00 PM	#2 (permalink)
Cyberman Registered User Join Date: Nov 2007 Location: Dillsburg, PA Posts: 545	Update: almost completely stripped I took a break from this project, cause I was getting frustrated with the weather. The truck is now back in the garage, and pretty much stripped down. Now come more issues and concerns. First of all, the driver side of this truck appears to have seen more wet weather than the passenger side. As shown in the pictures below, there is a nice crack and a hole in the firewall, on the outside of the wheel well. The entire underside of the rocker panel needs replaced. Lastly, the frame and upper control arms have quite a bit of rust. Everything seems like it can be repaired, except, I am by no means a welder. I am about to make a purchase at Eastwood for a frame restoration kit. I have vacation coming up in 2 weeks and was going to get to work on the frame. If anyone thinks different, please chime in. Any insights are welcome.

01-22-2008, 07:25 PM	#4 (permalink)
bigtrucknwheels Contributing Member Join Date: Jun 2007 Location: Selinsgrove, PA Posts: 2,066	cool to see someone giving one of these trucks the love it should have! awesome! keep the pics coming, Id love to see them! __________________ '97 4Runner SR5 V6. 4wd/V6/5spd. Factory rear locker, 2" OME suspension lift, 265/75-R16 BF Goodrich A/T KO's, Gray (in my case Blue/Red) wire mod. '90 4Runner SR5 V6. 4wd/V6/Auto. Complete Part Out! Click or PM! '90 Pickup Xtra Cab DLX. 4wd/V6/Auto. Soon for sale... :( '89 Pickup Std. Cab DLX. 4wd/I4/5spd. 3" BL. Soon for sale... :( ♪♪ Anything your Jeep can do, my Yota can do better. Mine can do anything better than yours ♪♪ Proud Sponsor22re Oil Cap Removed Thread

01-27-2008, 08:58 PM	#6 (permalink)
ocdropzone Contributing Member Join Date: Oct 2005 Location: PDX, OR Posts: 4,700	Sounds like the perfect time to SAS that thing Frame off is the way to do... __________________ ~Robb '81 Trekker The B4Runner Build TREKKER Forum Mini FAQ/Misc Ideas Thread TRY THESE SEARCH LINKS GOOGLE FOR TOYOTA WEBSITES LINK TO ONLINE FACTORY SERVICE MANUALS Drive a real 1st Gen Wheel Responsibly, Don't Screw It Up for Others

01-27-2008, 11:56 PM	#7 (permalink)
sh0kk86 Registered User Join Date: Mar 2007 Location: Phoenix, Arizona Posts: 657	wow, awesome work. while your at it, even though you said your no welder, got friends who can help reinforce the frame while you have the chance? mainly steering, and maybe the rear end of the frame?? por15 or some other rust preventing paint would be a good idea when your done w/ it. keep the pics coming man, must be a fun project to work on __________________ 1986 Toyota 22r Short bed Pickup \| 33x10.5x15 BFG MT's nick

01-30-2008, 03:52 PM	#12 (permalink)
tortis Contributing Member Join Date: Jul 2007 Location: shreveport, La Posts: 1,273	shocks are the least of your worries. the 3.4 would be sweet. goood luck on that score. __________________ 89 Truck X-tra Cab LCE Timing Chain 31'' Maxxis Buckshot 4.88's built by ZUK(the mind reader) Aussie Locker Front and Rear 63'' Chevy Springs Marlin HD Clutch Bilstein HD Shocks 2.5" Exhaust W/Dynomax Muffler 2-50 Watt Backup Lights

01-19-2008, 05:03 PM	#3 (permalink)
Cyberman Registered User Join Date: Nov 2007 Location: Dillsburg, PA Posts: 545	Thanks for all of your replies and input so far. I'll be on vacation starting 1/25. The frame will start to be restored then. More pics, body off the frame:

01-27-2008, 08:23 PM	#5 (permalink)
Cyberman Registered User Join Date: Nov 2007 Location: Dillsburg, PA Posts: 545	I got the frame rolled out, and in the other bay while the wife is away for the week. I was able to sandblast just about half of it. It appears I'll have to cut the torsion bar bolts off, they don't want to come loose. I should have up to the front suspension blasted and hopefully repainted by the end of the week.

01-30-2008, 02:59 PM	#11 (permalink)
Cyberman Registered User Join Date: Nov 2007 Location: Dillsburg, PA Posts: 545	Some more pics. I think this truck needed shocks. What do you think: Everything is off the front end, except the control arms. You'd think there would be enough leverage on the back wheels to just pick that front end up like a wheelbarrow, but no:

03-16-2008, 05:53 AM	#13 (permalink)
Cyberman Registered User Join Date: Nov 2007 Location: Dillsburg, PA Posts: 545	It's been a while since I've posted here, but I've made some progress this weekend. I finally got the frame coated in Eastwood's Rust Encapsulator and Chassis Black. It looks great. Now I have to do the same to the rest of the suspension components (front diff, rear axle, springs). It's finally starting to look like it's going to be worth while. Rust Encapsulator Chassis Black

03-16-2008, 06:52 AM	#14 (permalink)
SEAIRESCUE Registered User Join Date: Apr 2007 Posts: 491	Good job. Hope you don't burn out. Hope the wife is understanding. I suggest you find another cab. One picked over at the bone yard. If you had the option, one from a dry climate would be ideal. Rust sucks and the time you will put into fixing that rotten cab will be no more than finding a replacement and bringing it home. I have cut my share of rust out and patched. Its tough. MY $0.02

03-16-2008, 06:58 AM	#15 (permalink)
pwd Registered User Join Date: May 2007 Location: North Bay, Ontario Posts: 230	Awesome! I wish my frame looked like that, I love seeing people remove rust!!

03-16-2008, 06:24 PM	#20 (permalink)
isaac338 Registered User Join Date: Jul 2006 Location: Halifax, NS, Canada Posts: 849	did you brush that paint on or spray it? looks great! __________________ 1994 Xtracab pickup, 180,000km 1987 4Runner, 510,000km

03-22-2008, 07:11 AM	#23 (permalink)
Cyberman Registered User Join Date: Nov 2007 Location: Dillsburg, PA Posts: 545	Here's a few more pics. I actually put something back on the frame (w00t). A few more pieces coated, sry for the dark pic Before After

03-22-2008, 07:43 AM	#24 (permalink)
shoes138 Registered User Join Date: Nov 2006 Location: Folsom, Ca(near Sac) Posts: 456	wow awesome build!!!! hope everything works out great for ya!! that encapsulator looks like it works great! __________________ 89' 2wd Toyota Pickup - 3vz-e, Custom Cold Air Intake, Flowmaster Exhaust, Lowered Suspension, Custom Rims, Black Paint Job, Extensive Sound System to find out more Click here....http://www.cardomain.com/ride/437849/6

03-22-2008, 08:26 AM	#25 (permalink)
CoedNaked Registered User Join Date: Apr 2004 Location: Vancouver, British Columbia, Canada Posts: 1,473	Go and pick up some fluid film and coat your entire frame and suspension components with it. It'll protect the metal and the frame will bead water nicely. __________________ 1993 Xtra Cab Pickup \| 4x4 \| 3.0 - V6 \| R150F \| Silver-Grey \| Amsoil 10w30 synthetic oil \| Amsoil Synthetic Drivetrain fluids\| Borla Cat-back Exhaust \| OME HD Leaf Springs \| Bilstein HD Shocks \| Downey Idler Arm Brace \| Grey Husky Liners \| SR5 Bucket Seat Swap \| Color matched Canopy \| Yakima racks \| Line-X OTR \| Michelin LTX A/T 31 x 10.5 x 15 \| 323,600 KM's (202,250 miles) \| Made in Japan - Vin starts with "J"\| Fish on

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