Kurticus91's 2002 SR5 Build Thread

Today I put the truck up on my buddy's lift to do some work.

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I removed the original OEM muffler and installed a Borla Pro XS 40665 muffler. Out with the old, in with the new!

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I also installed a set of Spidertrax 1.25" hub-centric wheel spacers

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Took the opportunity to rotate the tires as well

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Many of the stock rear bumpers I have seen are rusting, and mine is no exception. It began to rust through to the exterior of the bumper creating pinholes and "streaks" of rust down the back.

I decided to apply some spray-on truck bed liner. Removing the bumper ended up being a hassle because a few of the bolts had rusted so badly that they couldn't be removed. I had to saw off the bracket ends with a sawzall to get the bumper free.

I sprayed some rust converted and rusty metal primer on the inside and about 4 layers of bed liner on the outside.

Came out good I think and it really looks sharp.

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About a month ago I ordered a standard length BajaRack through OK4WD. A few weeks later, and just in time for my upcoming beach trip, the rack arrived.

I removed my old cross bars, washed and waxed the roof to prep for the Baja.

Shiny!

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The truck looks good without anything on the top...

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It's here!

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Installation took about an hour by myself. I went for a drive to test out the wind noise, and to my surprise there isn't any detectable noise at 50 mph :clap2:

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I ordered a custom Satoshi grill from michaeljtomey and it arrived after a couple weeks. Removing the old grill was very easy, as was installing the new Satoshi.

Out with the old...

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In with the new!

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I LOVE the new look of the truck. michaeljtomey did an excellent job on the grill. If you want one, PM him for the details.

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Yesterday a big box arrived :)

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It was my ARB Bull bar. Part #3423020

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I was very surprised by the lack of organization from ARB. All of the hardware for installing the bumper was literally dumped into a single bag, all jumbled together. A list of the individual pieces of hardware made it possible to organize everything. I was eventually able to figure out what was what and where it went by tallying up everything and laying it all out. The instructions were pretty poorly written which didn't help much, but the parts list helped keep everything straight.

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Half of the hardware ended up not even being used since I was not installing a winch at the time.

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In order for the mounting brackets to be installed onto the frame/chassis I had to cut a notch into the brackets (complementing the notch on the frame) to get the bolt holes to line up and for everything to sit flush.

Here you can see the notch on the chassis preventing the brackets from mounting deeper:

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I had to cut a notch into the mounting brackets like so:

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After cutting out the notch, the mounting brackets will sit flush and the bolt holes will lineup allowing the stock tie-downs/towing hook to be bolted back onto the frame. I also used a 1/2" drill bit to drill out the small hole forward of the tow-hook/tie-downs which allowed me to run another set of bolts through the mounting brackets and the chassis for added support.

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Make sure the bumper sits level and everything is bolted down tight, and plug in your turn signals. Then go outside and drool at your new ARB!

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Some random pics from my last trip to the Outer Banks...
 

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more pics from OBX...
 

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The Outer Banks pictures look good, I can't wait to get down there this year. Did you do an annual pass or just the short term one?
 
The Outer Banks pictures look good, I can't wait to get down there this year. Did you do an annual pass or just the short term one?

Just the week-long pass. I'm leaving for the Navy next month so I wont be around to utilize a year pass, unfortunately
 
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