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Old 08-11-2020, 04:17 PM #1
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jfeltT4R Build Thread 2.0

I'm back and I'm starting over.

jfeltT4R Build Thread 2.0

Had a bit of an accident in 2017 (Totaled of course). Rather than take the insurance money and buy a different rig, I took it to repair the damage so I could keep the rusty hunk of junk that I had worked so hard on. Too sentimental I guess.

jfeltT4R Build Thread 2.0

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I found a '99 in a junk yard near me that had a good font end so I cut it off and welded it on. No frame damage aside from having to weld on new front body mount brackets.

The new fenders/hood were aftermarket and now have a nice patina to them as I never got around to painting. I completed the front end repairs in the spring of 2017 on weekends driving back and forth from Maritime school in NY. My back yard, canopy, and some beers were all that was needed to get the job done. The truck has been in the driveway for a year and a half as I now have another DD.

jfeltT4R Build Thread 2.0

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Some other things I did during the process:

*Scan Gauge II
*Glowshift Trans Temp Gauge
*New LBJ's
*New UBJ's
*Rebuilt front calipers and replaced rotors
*New radiator
*New A/C compressor and condenser
*New NGK plugs/wires

This was a great learning experience for me and further motivated me to build something that I had a vision for. I couldn't afford the time or cash to really go any further than I had at the time. I'm now much more experienced, with a deeper wallet ready to have fun and do it right this time.

This old rusty 98 SR5 is the perfect candidate for an overhaul

Last edited by jfeltT4R; 08-11-2020 at 06:32 PM.
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Old 08-11-2020, 04:58 PM #2
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Let's get the ball rolling here.


Frame:

The frame on my 98 has been rotting out ever since I bought it. I've replaced bits and pieces, painted with POR-15, done weld repairs....it's unstoppable. Last time I jacked it up it sounded like I was crushing up a ritz cracker. Time for a new(ish) frame.

After a long search I was able to find a relatively rust free frame in Virginia. It has some mild surface rust along various weld seams but had little to no inner rail rust. Great find in the Mid-Atlantic region!

I stripped down an old boat trailer I had in the yard and the frame sat perfectly on it. Ratchet strap and go!

jfeltT4R Build Thread 2.0

Had the frame blasted by a guy in town and he let me use his shop to coat it. After a lot of research I decided to stick with the trusty POR-15 with a top coat. I was concerned about adhesion after blasting the frame but I figured the metal would be porous enough. I painted the inner rails with Eastwood inner frame paint. The final product came out pretty good and I believe it will last a long time.

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

I went ahead and blasted/coated a pair of front LCA's, and rear control arms as well.



Rear Diff:

I bought a spare axle housing and 3rd member years ago with hopes of retro-fitting it into an E-locker housing. Although I could do it, I'm on the hunt for a clean E-locker housing and 3rd member.

I had the spare rear diff blasted and I coated it as well. If anyone is interested in the axle assembly feel free to reach out.

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0



Upcoming Plans:

I've had a set of SCS F5 16x8 -25 in matte dark bronze laying around that I haven't done anything with yet. Planning to run a 295 or 315 tire when I get to that point in the fall.

jfeltT4R Build Thread 2.0

I will be re-gearing to 4.88's once I have the tire situation figured out along with finding an E-locker rear diff.


As far as suspension goes, I'm likely going to stick with my OME 3" lift for now. 883's up front, 891's in the rear and Bilstein 5100 shocks all the way around. I received a set of JBA UCA's to fix the obvious issues caused by the stock UCA's. Not much info on the forums about anyone running these but I'll give them a shot!

jfeltT4R Build Thread 2.0



Bare with me as I will be head back to my ship next week and won't return until November sometime. At that point I plan on beginning to build everything from the ground up so when the time comes I can swap the body and be on my way!

Last edited by jfeltT4R; 12-02-2020 at 07:52 PM.
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Old 08-12-2020, 12:14 PM #3
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Looks awesome man, itís an awesome feeling getting back in a 3rd gen after a break. Good luck in your travels.


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Old 08-12-2020, 12:18 PM #4
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This looks like it's going to be a sweet build!
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Old 12-02-2020, 08:12 PM #5
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Home after a few months of working on the ship. Enough with working on big engines, time to get to work on the 4Runner.

jfeltT4R Build Thread 2.0

The day I got back I went and got the frame and trailer from storage to set the frame up on stands in the garage. Kind of having to set up a "new" workspace. Lots of lugging tools back and forth from the house.

I still have several items that need to be blasted and coated but for the most part I'm close to putting things together. Waiting on rear shocks, new steering rack, and a bunch of other little goodies.

Picked up a press from HF on black Friday to do new wheel bearings in all four corners. Trying to get my hands on some cheap press plates so I don't kill myself pressing out the front hubs.

Anyway, this is my current state of affairs. I've only been home about a week so expect to see some good progress shortly!

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Cheers everyone
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Old 12-15-2020, 08:05 PM #6
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Waiting on USPS especially this year has been aggravating but I'm working as I receive parts and special tools.

Today's completed tasks:

*Disassemble rear axles
*Disassemble, clean, & paint drum brake components
*Assemble rear suspension on frame (except panhard bar, still need to install eimkieth PCK)

As an aside, the donaldthebonald press tool for the rear axles is a must. Made the job a breeze!

jfeltT4R Build Thread 2.0

Cylinder's were pretty puch trashed on the exterior. I was able to needle off most of the scale and get them relatively clean to coat.

jfeltT4R Build Thread 2.0

Cylinder lining and piston seals are in great shape, should be just fine to re-use.

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Paint!

------------------------------------------------------------------------------------

Working by myself to assemble the rear suspension on a light frame was a bit of a challange but with a handful of ratchet straps I was able to compress/articulate to get shocks, springs, and control arms in.

Shocks: Bilstein B8's.

Springs: My old OME 891's. I did not see any apparent sagging over the time I had them on the old rig so I had them blasted and re-coated for reuse.

Upper and lower control arms: factory

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

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Pretty good day for me. The cold is starting to get to me so it's time to fill up the propane tanks and get the heater going...

Maybe installing new steering rack tonight!
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Old 12-17-2020, 11:11 AM #7
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Can't wait to see what the end result is going to be!
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Old 12-17-2020, 08:08 PM #8
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Pretty productive day, hoping the trend continues.

Today's completed tasks:

*Install poly bushings into new steering rack

*Install steering rack (left loose so I have wiggle room when installing cam adjusters).

*Press out front hubs and prep for blasting/coating

Steering Rack:

Pressed out OEM bushings to replace with the TC Poly bushing kit. Used a basic ball joint service kit and an impact. Made for quick work.

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

Final Product:
jfeltT4R Build Thread 2.0

The engery suspension bushing kit I have previously used came with a washer that mounts between the rack and the frame where the long through bolts goes. The TC kit did not come with one and after setting the rack in place, it definitely needs a washer. Just picked up a 5/8" washer from my local ace.

But anyway, here is the rack installed and ready to be torqued whatever year I finish this project. (Waiting on the new bushing bracket to come in the mail)

jfeltT4R Build Thread 2.0


Front Hubs

I want anything and everything practical to be new/rebuilt on this build. So with that being said, might as well do the wheel bearings and seals while I have the opportunity.

This job was pretty cumbersome without an extra set of hands. Press plates and the whole kit and kaboodle hit the deck multiple times while setting up. But with the right press plates and some other little items the pressing itself is relatively simple.

The only real hiccup I had was after removing the hubs, the bearings had loaded up into the snap ring. The last set I did it only took a few taps of the bearing with a dead blow and I was able to move them back enough to take pressure of the snap ring. This time was another story... I had to beat the bearings into submission. A brass punch and a BFH worked for me.

Pressing out hubs with a 35mm socket:

jfeltT4R Build Thread 2.0

Pressing out bearings: I offset one of my ball joint tools in the hub to contact the inner and out races. This isn't the ideal way of doing it but it works.

jfeltT4R Build Thread 2.0

Everything out:

jfeltT4R Build Thread 2.0

I will use the descaling gun and wire wheel to clean up the knuckles before sandblasting and press all the new goodies in when that's all done.

Tomorrow's plan is to finish the press work on the rear axles then enjoy the weekend.
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Old 01-05-2021, 09:01 PM #9
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The holidays really slowed things down. Getting back to work now!

Tires

Ended up going with 295/75/16 BFG A/T's. I've had a couple sets in the past and will likely never get anything different.

The tire shop mounted them on my SCS F5's and scratched/chipped paint on all four wheels at the hub after i begged them to be extremely careful. Really really sucks adding that to the list of issues to solve. But all that aside, here they are.

jfeltT4R Build Thread 2.0


PCK Install

Picked up a PCK from @eimkieth and welded it in on Christmas day. Came out pretty good and I'm excited to feel the ride difference once this thing is on the road.

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

Strut Reinforcement Plates

Also welded on some strut reinforcement plates that came from @eimkieth as well. I don't think I really needed them but can't hurt right?

jfeltT4R Build Thread 2.0


Spindle Builds

I ordered the TC spindle gussets and welded them on before sandblast. Everything came back from sandblast/coating yesterday so I got right to more press work.

There are a few write ups on the forum on this job so I'll just keep what I did simple.

1) Press in new bearings:

*Use one of your old bearings as your press tool as to evenly distribute force over the inner and outer races.

jfeltT4R Build Thread 2.0


2) Install new snap ring and outer dust shield:

*You can work the new snap ring in by hand, no need for and kind of pliers.

*use a small piece of 2x4 and tap the outer seal into place. Mine were
especially difficult to press down evenly.

jfeltT4R Build Thread 2.0


3) Press in new hubs:

*Be sure to support the inner race of the wheel bearing from the bottom
when doing this.

jfeltT4R Build Thread 2.0


4) Drop in ABS rotor

5) Gently press the spacer in with the bevel facing inboard. The spacer should be free to spin on the hub and independently of the ABS rotor.

6) Install inner dust shield

7) Check for and kind of binding or inconsistencies. These are big a** bearings. They should rotate smoothly with a light resistance when spinning by hand.

Enjoy some clean and proper knuckles!

jfeltT4R Build Thread 2.0

As an aside, I generally opt against using any kind of grease on interference fit components. I made an exception here and use the slightest amount just to aid in assembly (hopefully won't need to aid in disassembly!)

Just waiting on a special tone ring tool for the rear axles and then I'll finish the press work on those. Lots of itsy bitsy busy work in the meantime.

Last edited by jfeltT4R; 01-05-2021 at 09:21 PM.
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Old 01-05-2021, 11:59 PM #10
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Great job.Your ground up build is super clean and professional. Looking forward to the rest of the build.
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Old 01-06-2021, 12:18 AM #11
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I wish I could swap out my rusted frame with a fresh one but it would look really goofy doing it in the driveway of my complex. My frame is still very solid though.
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Old 01-06-2021, 10:10 AM #12
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Quote:
Originally Posted by spartacus View Post
Great job.Your ground up build is super clean and professional. Looking forward to the rest of the build.
Much appreciated! I want this thing to have the cleanest bones around!

Last edited by jfeltT4R; 01-30-2021 at 10:21 AM.
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Old 01-06-2021, 10:23 PM #13
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Quote:
Originally Posted by jfeltT4R View Post
Much appreciated! I want this thing to have the bones around!
super nice work. I did pretty much the same thing.

check out PartSouq Auto Parts Around the World they have OEM parts at much better prices and they ship it from the UAE in like 3 days. I can get parts from UAE to MN faster than toyota USA can ship them to me from Chicago. go figure.

your top plates you posted about on partsouq are like $38 + shipping so that gives you an idea how much the USA toyota suppliers jack up the price to gouge you.


My frame replace starts about here or so...
1997 Sketchy SleepyDad build

cheers man waiting for more posts

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Old 01-07-2021, 09:35 AM #14
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Quote:
Originally Posted by sleepydad View Post
super nice work. I did pretty much the same thing.

check out PartSouq Auto Parts Around the World they have OEM parts at much better prices and they ship it from the UAE in like 3 days. I can get parts from UAE to MN faster than toyota USA can ship them to me from Chicago. go figure.

your top plates you posted about on partsouq are like $38 + shipping so that gives you an idea how much the USA toyota suppliers jack up the price to gouge you.


My frame replace starts about here or so...
1997 Sketchy SleepyDad build

cheers man waiting for more posts

Thanks for the info! I've had pretty good luck with partsouq and mcgeorge. Results vary on different parts so I pick and choose. Pretty much everything down to the nuts and bolts on this build will be OEM. (Things that matter anyway).

Just checked out your thread, awesome work! Gives me some extra inspiration.
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Old 01-30-2021, 10:14 AM #15
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Moving right along

Made a bonehead move with the front spindles. I forgot to add the JBA UCA adapters before welding on the gussets. This didn't allow any room for the adapter pieces to get pressed in from the bottom up.

I ended up just slotting the upper hole up a little ways so the diameter of the adapter could clear (didn't end up looking too horrendous). These adapters went in tight!

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0



Rear Axle Press Work

This was a bear without an extra set of hands. Here's how it went

Parts:

jfeltT4R Build Thread 2.0



Installed new bearing and outer seal:

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0



Press on outer spacer:
(The bearing popped out of place 4 or 5 times while walking the axle over to the press...easy way to lose you sh**)

jfeltT4R Build Thread 2.0



Install snap ring:
(you'll hate yourself if you forget to, don't ask how I know)

jfeltT4R Build Thread 2.0



Press on the ABS ring and inner spacer:
I flipped my spacer as per recommendation with new axle seal P/N

jfeltT4R Build Thread 2.0



I started at approx 5mm of polished axle to begin the grease test after installing the new axle seals.

jfeltT4R Build Thread 2.0



Install new axle seals:

jfeltT4R Build Thread 2.0

jfeltT4R Build Thread 2.0



Perform grease test:

I did not have the 3rd member in the axle housing when doing this which may not have given me the most accurate results with the slight bearing deflection. Close enough for now and I will check again once I finish re-gearing.

My final results were 5mm (R) and 6+ (L). I would have loved for them to be the same but I think this will work. Grease test showed center contact on both inner spacers.

jfeltT4R Build Thread 2.0



Starting to look like something

jfeltT4R Build Thread 2.0



Finishing up the front suspension is next and then back to work for a few months. Cheers
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