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Old 07-28-2018, 07:35 PM #16
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Agonizingly slow going here lol. Shock tower gussets mocked up with the frame and tower metal prepped and ready for glue. No welding experience. The one regret that's eating at me now.....
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4318-jpg
On the positive side,
Total Chaos fitment on the pass side gussets looking pretty damn good out of the box tho. Hoping the other side is the same.
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Old 07-28-2018, 08:20 PM #17
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Spindles welded and painted.
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Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4319-jpg 
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Old 08-08-2018, 12:36 PM #18
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Mock up/test fit

Just checking the hoop and secondary and how it lines up with the LCA mounting bracket. Trying to at least go through the fit and clearances of everything before she gets a ride on a roll back over to the welders. Prep work is done for the cam tab and tower gussets. Lots of shiny metal. Really wish I could say I did the welding on this project, but I'm not gonna try and learn "how" on these critical parts.
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Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4323-copy-jpg 
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Old 08-10-2018, 02:48 PM #19
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Here is everything mocked up (pass. side) with the hub installed. Have to put on roller tires for the tow truck over to the weld shop. Anthony over at Apex Fabrication-Merritt Island, will be ready to go on Monday. Still have to put the drivers side together over the weekend. I've outlined a couple tips for the tower gussets and where the reservoir brackets and the Boss (lower hoop support to the frame) gets welded to the shock hoop and frame. @TOTAL CHAOS everything is going together quite nicely w minimal cutting and grinding on the tower gussets. Thank You!!
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Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4324-copy-jpg 
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Old 08-12-2018, 09:37 PM #20
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Originally Posted by 4RunnerAquasport View Post
Here is everything mocked up (pass. side) with the hub installed. Have to put on roller tires for the tow truck over to the weld shop. Anthony over at Apex Fabrication-Merritt Island, will be ready to go on Monday. Still have to put the drivers side together over the weekend. I've outlined a couple tips for the tower gussets and where the reservoir brackets and the Boss (lower hoop support to the frame) gets welded to the shock hoop and frame. @TOTAL CHAOS everything is going together quite nicely w minimal cutting and grinding on the tower gussets. Thank You!!

Great job! Thanks for posting progress pics

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Old 08-14-2018, 12:49 PM #21
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Pearl took a ride to the weld shop yesterday. Thank you Anthony Silva at Apex Fabrication!! Thank You Timbo at Timbo's Customs for doing the prelim work on the Cam gussets. Now to tear it back down and paint.
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4325-jpg
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-tc-cam-gussets-jpg
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Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-apex-fab-3-jpg  Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-apex-fab-jpg  Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-apex-fab-2-jpg 
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Last edited by 4RunnerAquasport; 08-17-2018 at 06:57 PM. Reason: adding a picture
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Old 08-17-2018, 06:40 PM #22
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Needing to prep all the suspension and frame metal for paint, but I can't find the motivation in this Fla heat.
So I have some Centric 5th gen calipers going on the front and they need to be painted. Here is an idea I came up with to mask the pistons. 4 standard size rattle can tops, with 2 cut at about 3/4" and some cardboard wedged between them. It might work.....
Attached Images
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4327-jpg  Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4328-jpg 
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Old 08-20-2018, 06:41 PM #23
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Dorman hubs-smaller knurl opening-STOCK DIAMETER KNURL WON'T WORK

Ordered Matrix studs (#610-463, M12x1.50 14.2 mm knurl, 55 mm length) to work with my wheel spacers and figured out that Dorman hubs are only 13.3 mm diameter knurl opening.
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4330-jpg

OLD STUD 13.6 MM

Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4332-jpg

MATRIX STUD 14.2 MM

Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4331-jpg

Cross referenced a new stud for ford products Dorman #610-376, hopefully it will fit.

Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-screenshot_2018-08-20-dorman-products-610-376-png
This was quite the brain teaser for a few minutes because Dorman doesn't list the knurl diameter for this hub. So I really scoured the web for an answer, even considered drilling, thought better of that and went back to Dormans site and looked through all the sizes they offer. PIA!!! Lost a half a day researching this crap.
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Old 08-24-2018, 07:35 AM #24
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Dorman hubs-smaller knurl opening

Well my cross referenced stud (Dorman #610-376) worked out pretty well. The knurl diameter seems to be right and the length is perfect for the 1.25" spacers. Ordered the All Pro "Extended Thread" lug nuts. Hopefully the outer diameter will work with these spacers. If not I think the Acorns have enough thread to work sufficiently.
Attached Images
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4334-jpg  Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4333-jpg 
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Old 08-28-2018, 09:49 PM #25
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Got her back up and running. Still have a lot of shakedown and test drives to do. The 315s are rubbing the secondary res before full lock both sides. I think I can get rid of some of that by moving the brackets a little inboard. 5th gen calipers seem to be working good. I got the new pads and rotors bedded in today as well.
AND my sliders came in today so I put them on this evening. Pearls lookin a little tougher now.
Attached Images
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4339-jpg  Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4340-jpg 
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Old 08-29-2018, 01:34 PM #26
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Had a pretty bad "creaking" sound from drivers side. It's not Halloween yet, so no creaking allowed! Upon investigation it was the hoop making contact with inner fender well. Trying to address that today.
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4343-jpg
Here is where the secondary res is getting contact from the BFGs on both drivers and pass side. Hence the packing foam and tie wraps until I get it sorted out. R&D work is on the back burner for now, going back to work so no time off until the end of Sept.
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4342-jpg
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Old 08-30-2018, 10:07 AM #27
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Total Chaos-Alignment is good to go!

Just got back from Firestone-Merritt Island, Fl. My alignment tech for a couple decades now, Steve Locklin earned his $20 tip, and dialed her in perfectly. He has done lifted trucks now since the 70s, even owns a lifted vintage mid 60s Ford, and has been doing my 5th gen for years now. Gave me as much Caster as he could to help clear the reservoirs in the back of the fender well. I forgot to tell my welder to tuck the res brackets inboard as far as he could. So they will be relocated in the near future as I think there is a 1/4 to 1/2" more clearance to be had. Alignment tech said the TC Cam Tab Gussets worked really well and I was only 3/16 toed out on my eyeball adjustment lol.
Pearl be Drivin Great!
Attached Images
Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4348-jpg  Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-img_4347-jpg 
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Old 08-30-2018, 11:22 AM #28
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Whoa an alignment tech that knows what they're doing! looking good!
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Old 08-30-2018, 11:37 AM #29
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Whoa an alignment tech that knows what they're doing! looking good!
Thanks!! That's why I give him the $20 tip lol. I used to take my lifted Fords and Chevys to him back in the 90s at Tire Kingdom when he worked there. This Firestone won't cover the Lifetime on the full TC set up because there is nothing factory left on it. I really don't blame them tho, it would be a slippery slope with customers that don't have a clue. They will do Lifetime for me on the 5th gen with just the TC uppers. I need to talk to him about a training a protege so when he retires I won't be searching for another guy lol.
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Old 12-30-2018, 04:14 PM #30
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4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of 4RunnerAquasport has much to be proud of
Pearl gets a Nip/Tuck

RB BL 1" w new OEM BM Bushings.

Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-4th-gen-bl-jpg

Pearl's mod/build LT rear/DK +3.5 LT/Custom Baja Bumper/Thorley Headers/Manual T-case-bushings-jpg
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1988 DLX 22RE AUTO BLACK-"Granny" - SOLD
2003 SR5 SPORT V8- Build- "Pearl" You Tube 2UZ 120
2012 LIMITED V6 "LE Mae" 5TH GEN BUILD THREAD
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