sluggercz's '05 Build Thread

Satoshi

Just got done with the finishing touches on my Satoshi mod:


Now I just have to wait for my DO Front bumper for me to install it.
 
Exhaust from Dirty Deeds

Talked to Keith at DirtyDeedsIndustries today to get an exhaust built, going to get it installed on Saturday as well as having my tail pipe routed to the side. From the phone call alone I can tell Keith definitely knows his stuff, we settled on a 5"x18" muffler with 2.5" piping, with his Helmholtz resonator included as well as free installation.
He explained some of the intricacies of developing a properly built exhaust, and the improvements over Toyota's factory exhaust - too detailed for me to accurately retell, haha- but if you want to read more about his design process there's a great post on TundraSolutions: How a properly built exhaust system works.

I'm in the process of recording some audio samples of the stock exhaust, and once the new one is installed on Saturday I'll update this post with some new audio clips as well as a quick review.
_________________________________________________________________________________________________________________________________________________
Stock Exhaust Audio, 3' directly behind
 
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zopperman said:
do you have 06+ headlights? You may have fitment issues with the grille's subframe with stock 03-05 headlights.
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Nope, have the 2005 headlights retrofitted. I have test fitted the grille and the only clearance issue I ran into was between the grille and bumper itself - which will be a non-issue once my Demello bumper is ready; I figure being patient and not cutting into my stock bumper just to be able to fit a new grille will pay off in case I decide to sell the stock bumper in the future.

BTW I like the new signature pic, looks tight
 
sluggercz said:
Nope, have the 2005 headlights retrofitted. I have test fitted the grille and the only clearance issue I ran into was between the grille and bumper itself - which will be a non-issue once my Demello bumper is ready; I figure being patient and not cutting into my stock bumper just to be able to fit a new grille will pay off in case I decide to sell the stock bumper in the future.

BTW I like the new signature pic, looks tight
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thanks man. I'm shocked you didn't have any issues. I'm still fitting mine, it's been two months. I hit the subframe on the headlights. The 03 headlights go \/ while the 06+ go /\ so the subframe has a spot to rest. Good call on waiting for the bumper, i trimmed the grille instead of the bumper and just removed the black trim piece.
 
HB 4X4 said:
Nice looking build!
Click to expand...

Thanks man

zopperman said:
thanks man. I'm shocked you didn't have any issues. I'm still fitting mine, it's been two months. I hit the subframe on the headlights. The 03 headlights go \/ while the 06+ go /\ so the subframe has a spot to rest. Good call on waiting for the bumper, i trimmed the grille instead of the bumper and just removed the black trim piece.
Click to expand...

Yeah I didn't want to compromise what the small amount of structural integrity the grille had after removing the center piece; the only place I do get some rubbing is between the grille subframe and the trim pieces that shit below the headlights. It's no more than a couple mm's of overlap so I'll probably just sand both surfaces down a bit.

Last thing I have to do is get a longer piece of metal rod for the grille latch as the 2005 latch sits about an inch higher.
 
sluggercz said:
Thanks man



Yeah I didn't want to compromise what the small amount of structural integrity the grille had after removing the center piece; the only place I do get some rubbing is between the grille subframe and the trim pieces that shit below the headlights. It's no more than a couple mm's of overlap so I'll probably just sand both surfaces down a bit.

Last thing I have to do is get a longer piece of metal rod for the grille latch as the 2005 latch sits about an inch higher.
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You can use some solid 14 AWG copper wire.
 
sluggercz said:
That could work, I was also thinking of using a brass brazing rod - it seems to be the right thickness.
Click to expand...

Good idea. Can you do me a solid and take some pics of the fitment of your grille when you have a chance? I'm struggling not to cut out the spot welds on the subframe on the driver side where the metal frame is rubbing against my headlights. Grille has been sitting on my mantle for months since I can't get the fit right and don't know how to weld if I cut of the frame. i bolted it together through an existing hole so hopefully that will hold.

You didn't shorten the grille, did you?
 
zopperman said:
Good idea. Can you do me a solid and take some pics of the fitment of your grille when you have a chance? I'm struggling not to cut out the spot welds on the subframe on the driver side where the metal frame is rubbing against my headlights. Grille has been sitting on my mantle for months since I can't get the fit right and don't know how to weld if I cut of the frame. i bolted it together through an existing hole so hopefully that will hold.

You didn't shorten the grille, did you?
Click to expand...

Nope didn't shorten it. Do you want pictures of the grille on without the bumper or just want to see where it overlaps the headlight trim? If you shortened the grille I would assume it would fit just fine, unless your headlights are slightly closer together than mine are.

Thinking about it though, it may be rubbing more because you've moved the steel subframe up and therefore it contacts more of the headlight when you close the hood.
 
Awesome build thread! Love the documentation on all of the mods.

Also - The pics from the Mojave trip looks awesome, I would love to head out there if you go again!

I see you're pretty local too and did Maple Springs, thats really close to me!
 
Dirty Deeds Exhaust

Went down to Dirty Deeds in Escondido this morning and got to hang around the garage while Keith got the exhaust fitted - had to fix the jig to fit the V8 exhaust as it differs in length by about 2" compared to the V6.

Here's some pictures from the day:

Keith's Tundra:



Exhaust before being painted and fitted with a Helmholtz:


Dirty Deeds Industries:


A pair of his prototype UCA's:


4Runner on the lift:


Had a FJ roll in rocking a nice color scheme going on, also running the newer Dirty Deeds UCA's:


Exhaust tip routed to the side & resonator removed:


Shots of the exhaust installed:







My quick review:
Exhaust now sounds beast, not too loud, zero drone, but the depth and clarity of the exhaust note is awesome. Also liking the black color scheme, and the exhaust tip routed to the side does get rid of some of the exhaust smell (as well as looking great).

Words can only say so much, so I'll let the audio clips do the rest. They should be posted by noon tomorrow.
 
sluggercz said:
Nope didn't shorten it. Do you want pictures of the grille on without the bumper or just want to see where it overlaps the headlight trim? If you shortened the grille I would assume it would fit just fine, unless your headlights are slightly closer together than mine are.

Thinking about it though, it may be rubbing more because you've moved the steel subframe up and therefore it contacts more of the headlight when you close the hood.
Click to expand...

Yeah, i'd like to see how it fit with the headlight trim.

This is my subframe:
 
[MENTION=55855]zopperman[/MENTION] Looks like that silver bracket you bolted on there is definitely hitting the headlight - what's the reason for that thing anyways?
 
sluggercz said:
[MENTION=55855]zopperman[/MENTION] Looks like that silver bracket you bolted on there is definitely hitting the headlight - what's the reason for that thing anyways?
Click to expand...

Nope, it finally clears now



Here is why:

I had to cut the cut the frame and the bottom piece out and move it up



see how its holing the pieces of the frame together? They dont join up at the right angle since you shorten it

 
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