This sort of piggybacks off my sas thread ( https://www.yotatech.com/forums/f152...t-swap-181363/ ), I figured I'd split up the swap with the rest of the work to make it easier search for and pull info out of etc.

Building a relatively self sufficient, expedition type rig, I know "expedition" gets tossed around a lot as a truck descriptor when in fact its a rig with just a mild lift and 33's essentially just an on / off road DD. While my build may not be as extreme as some it's being set up as something we can live in during the length of a trip up the intercontinental highway in a few years, but first will cut its teeth in the Puerto Rico mountains and jungles. Plan to start with is just the basics:

Hot water shower w/ water tank
Dual Batteries
New in floor sub mount and hidden amp
Bed organizer / sleeping platform
In bed spare tire mount
Tinted lexan windows in canopy w/ security screen inside
Tinted & Security laminated cab windows
LED lighting in & outside canopy with in canopy switch panels, all on a quick release so I take off the canopy when around town if I want.
Tune up w/new fluids everywhere and new timing belt

And here's the first bit to start!

New intake to fit 2nd battery:



Some Goodies

New front axle brake lines, rear pinion seal, shifter bushing and cup, Painless dual battery kit, and 4 12" white LED strips to illuminate the inside of the canopy.

New flush sub mount:


Will put up a shot of my old box soon.

Now I just need to decide on my batteries, I've got a $52 credit for a Sears battery because my old one was still under warranty. I've done a bunch of research but I still can't figure it out, why couldn't you run one deep cycle for the accessories and one regular for the standard truck needs if they're on an isolator?

 

Progress and new goodies!
2 Diehard Platinum group 34's 880 CCA & 135 min reserve, AGM like an Optima but with a 4 year free exchange warranty:


E-codes with 80/100W Hella xenons, Redline Shockproof gear oil and MT-90



Had to relocate coolant overflow again to fit the larger group 34 rather then the 25 I had mocked in first...

She's a tight fit!

 

Damnit, must've deleted that post somehow...anywho

Picked up some more new goodies; water tank, pump, hoseing, shower head, timing belt and water pump to go along with new cap, rotor, plugs, wires etc.



Started work on the heat exchanger to make hot water for the shower;
an 18" long 2" copper pipe with caps
3 1/4" x 17" coils inside
caps



All together


Pulled the seats and console out to get a bit more working room inside for some wiring, also old sub box:



Had no 5th gear or reverse when pulled her into the shop so figured I'd give Marlin's shift bushing and cup a go before pulling the tranny to replace it:

Could be a small factor in the problems, nice tear in the boot, fixed it up with good ol shoe goo!

New bushing:

Most guys find ground up remnants of the old factory rubber bushing when they pull it apart, well 415,000 miles has taken it's toll on this one and there's nothing left just metal on metal!!


Then turned attention to the switch and lights for the dual batt set up:
Nice and clean

Mounted the lights in the same switch blank off as my alarm LED


And wrapped up the wiring under the hood:

 

somethings up, the last 2 posts haven't posted and have had to be redone

Anyways got the rear cut for the water tank:



Test fit:



Not quite in all the way, after a bit more trimming and a new piece of steel to rebox the rear crossmember:


Couldn't hold it in place and get a photo so that will come later once I get some brackets fabbed up.

New wires and got the amp remounted:



Got the wife involved with a can of spray foam!!



and some cleaning...



While I got the sub mounted:



and started pulling apart the front of the motor for the water pump/thermostat/timing belt:

 

nice build up, i see it is commin along pretty well, and good job of getting the wife out of the kitchen and helping out on the in rig a little.

 

sick build man you got some unique plans with that truck i like it. cant wait for more.

-matt

 

Timing belt all finished, new belt, water pump, Toyota thermostat, cap rotor, plugs and a fresh fill of Shell Rotella-T synthetic 5-40 with a Napa gold filter:

looks same as it did a few days ago

Got spare tire mount all built up and modified to fit flush with the top surface of the tire when mounted in the bed so that the sleeping platform will fit as low as possible:

fits great, got the holes in the bed all drilled and siliconed to keep em black to match the linex and prevent rust.

and a couple little teasers of the wood work:



Wooo hoooo stoked on how it looks so far, going to have 2 pull out drawers in the back, the rear side compartments will have flip open lids, there will be a full removable panel over the spare so it's still easy to get to!

 

currently i have my spar in the same location with my platform above with 2x4's going across from diver to passenger. under neath its all open so I could optimize storage ( I need to take some pics. of it ). Im interested to see your strategy with access to your small compartments.

 

this is awesome! subscribed

 

Thanks guys! got a bit more work in tonight getting the frame all bracketed and bolted together and started staining / water proofing! More photos coming tomorrow of it hopefully all together!

 

Love the project.

I'm just curious as to how much of a pain in the butt it's going to be to get that tire out of there.

 

RobD - it's going to be a bit of a pain, not terrible but not simple either...in addition to shown above there is a second layer to the section around the tire to make it 1.5" thick and the whole part of the platform above the tire slides off as a hatch...theres a 2" gap around the tire to make it easier to manipulate a bit. Will put up some more pictures later tomorrow of the bed all assembled.

Just finished changing plugs and all fluids; MT-90 in tranny and shock proof in the rear (napa in the front for the break in) - lesson learned, shockproof heavyweight gear oil does not flow in sub freezing temperatures (damn you winter!!! )

pics coming later tonight!

 

alright im waiting for the new pics

 

I'm just trying to imagine lifting it while you're laying on your stomach in the confines of the canopy. I might contemplate making that divider removable, plus your drawer section, to allow you to drag the tire out through that "tunnel", instead of hoisting it from a funky angle.

 

I'm just trying to imagine lifting it while you're laying on your stomach in the confines of the canopy. I might contemplate making that divider removable, plus your drawer section, to allow you to drag the tire out through that "tunnel", instead of hoisting it from a funky angle.


You could always put a lifting eye above the tire and use a rope or something to lift it out of the hole then deal with it after. Of course that would involve reinforcing your topper to handle the weight of the tire and rim.

 

Alrighty pics as promised!! Sorry forgot camera outside last nightm finished up around midnight so was too tired to go back out!

Got all the rest of the wood cut and stained:




Got a bit cold outside so had to bring it all in by the wood stove for the night to make sure it dried!



On to tail lights, out with the old in with the new!

Sprayed the black surrounds on the new o.e ones body colour silver for a bit of something different


And after siliconing the holes and bolt heads on the tire mount overnight, put it all in and tightened her down:

(oops a little too tight, bent the top cross piece a bit )

More in the SAS thread and to come later....only 2 more days till it gets shipped!! Ahhhh,
Still gotta:
Install LED camp lights in / outside truck and canopy
Wire switch panel for lights
finish brackets for water tank with skid plate
install and plump water / shower system
add coolant hook up batteries and fire the beast!

 

Oh and yes, the divider etc. is removable if needed but it can be weaseled out the top while sitting up on top of the sleeping platform, tried it out first before we finished cutting everything! Just hoping we wont have to be using it much!

 

nice build man

 

Thanks guys !

Got the engine all wrapped up and ready to fire, hoses, coolant etc. all back on


And replaced the leaking clutch hydraulics with new hoses and slave cylinder, this one was fun to do!

(the black rubber hose running vertically in the back of the picture)

Brackets and skid plate for the water tank all fabbed up and drying:




And started mounting up the LED camping lights around the truck:







There's going to be 10 all up, 6 exterior and 4 inside the canopy on 5 different circuit controlled through a switch panel in the bed.

 

Alright got the sleeping compartment 90% done and had to half-ass a bit to get her done in time but it turned out alright...though realized one panel forgot to get stained / sealed !




The new tail lights with the body coloured surrounds:



Water tank all mounted up:


And all ready for the shipper:




Turned out pretty well, still need to wire in the lights and plumb the shower but all the main parts are in place and ready to rock once it finally gets here!!