The Expo Dawg Project -- 2nd Gen '95 T4R

Scalded_Dawg

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SOLD: The Expo Dawg Project -- 2nd Gen '95 T4R

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Here she is, current state (5 May 2015)
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SO... I've had this 2nd Gen '95 4Runner SR5 since Sept of last year and just haven't put together a build page. Now that I've done a few things worth reporting on a build page, I figured I'd put one together. Here is her story:

I picked it up off of CraigsList locally for $1200, it had some engine issues (explained below) but ran, no rust underneath, body is really straight and interior only has a few minor wear problems. Had 158K miles on the truck at purchase. The main purpose of this truck is a project vehicle. It is an expedition build with good road manners, drivability and moderate off road capability. I want to be able to go out hit some trails and see stuff - off the highway - off the beaten path. Most mods will be focused towards that goal.

Here she is the day I brought her home:
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She had a slight smoking habit:
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#6 Spark plug looked like this:
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And it's matching cylinder:
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I believe the PO had a blown head gasket that they drove on for a while then had it repaired but by that time it had damaged the cylinder; it was burning oil bad in the #6 cylinder. This was more than they wanted to repair so they just drove it some more and sold it. It would smoke really bad for about 10 minutes after start up but finally get hot enough to burn it all out. Honestly, it ran pretty rough... LOL!
Since it had this problem and the rest of engine was an unknown condition to me, I went ahead and rebuilt the whole thing, heads included.

Some minor drama involved here... the original block had been rebuilt by Toyota on a subcontract with Jasper engines (most were in the days of the head gasket recalls). Apparently, in the subcontract they just repaired the damaged portion of the engines, this block's #6 cylinder was MAX bored .060 over, all others were still stock sized... the original block was worthless. I found engine another in a salvage yard and bought the entire engine, intake to oil pan, for $300. I tore it down and took the second block to my machinist; it was rebuildable. hat engine was junked due to a spun rod bearing. He tried to re-use the second crank but it exploded in the turning lathe :eek: So we used the original crank. Also found one of my original heads and been reworked poorly, so I used one of the second engines heads to replace that as well. That junk yard engine was well worth it in the long run.
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IN this pic you can see the new injector wire pigtails. I installed the FlameThrower 4 Hole injectors for increased atomization of fuel. Are they better? Frankly the engine ran so bad before, any thing is an improvement! I'm certain they perform better but I don't have much previous reference to judge against.
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Ran into a few problems during the final stages of reassembly... this one head had two holes that the threads stripped right out of (YES, I was using a torque wrench):
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Prepped for surgery: I got some HeliCoil inserts to replace the stripped threads; drilled out the hole, tapped new threads and screwed in the inserts. Easy stuff!
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Ready to drop; in this photo
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This engine rebuild brought to you by:
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Back on the road (Nov 2013):
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After I got it back on the road, I drove the crap out of it for a couple months.
This helped to make sure the rest of the drive train was good to go and wring out any more bugs.

First big mod to complete was the lift. I used 1.5" ball joint spacers for the front (side to side leveled with the torsion bars) and the rear coils springs from a '93 FJ80 Land Cruiser. (gained +1.75" on each side in the front and +4.5" of lift in the rear).
The ball joint spacers are really straight forward to install. The FJ80 springs aren't difficult but the are considerably longer coils so you nearly have to completely remove the rear end to get them installed. I also built a pan hard top bracket; completely jacked the design from 4Crawler. I didn't take any pics of the lift install but here's the results...
Before:
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After:
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Next major mod was a custom front bumper build. I didn't like any of the available bumpers for the 2nd gen T4Rs, so I borrowed several aspects of bumpers I liked and built my own.

First built it out in foam board:
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Spent a disgusting amount of time cutting all these pieces out of 3/16 plate steel with my angle grinder with a cutting wheel:
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Time for some of this
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I bought this frame beef up plate to save some fab time
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All this mil scale on the plate steel is a ***** to remove... until I figured out the acid bath trick
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Time to tack it all together; this center box winch plate is 1/4" for the winch mount and down to the frame mounts
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I had a professional weld up the center winch box due to it all being 1/4" steel and my little welder would barely do 3/16" with prep work
After getting it back I was able to finish it up:
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Primed up with etching primer:
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Decided to paint it with this:
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Installed:
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I chose to put these very small turn signals in the bumper corners to replace the stock location ones; they are actually really bright.
I did have to also install an LED resistor to stop the hyper flashing:
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Next was a couple of maintenance mods:
LED cabin lights:
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New brakes and front hub spindle bearings
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Went with an upgrade of slotted and cross drilled rotors with ceramic brake pads
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Also found these manual hubs locally. Changed out the drive spindles on my ADD front to save some wear and tear on the front drive train.
These just needed some clean up and fresh paint... good as new:
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Time for some of this:
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Got some new shoes:
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Using the Tacoma Sport rims on the new shoes; backspacing is VERY different.
This is the stock rim/tire side view:
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This is the new shoe/rim WITH a 1.5" wheels spacer; only sticks out about 1/2" further than stock:
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A few other minor mods:
Some red LEDs in the map lights:
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Radio Auto Antenna Kill Switch:
Just tapped into the antenna command wire and put in this simple kill switch. If I'm going thru tight trees or brush I can lower the antenna... keeping me from ripping it off.
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CB Radio and Antenna mount:
So I went with the Cobra 75WX/ST radio and a Wilson 1000 antenna w/ magnet mount. I plan to build a roof rack later and will incorporate a hard mount into that, so the mag mount is just temporary.
I drilled a hole in the front side of my third brake light housing and ran the antenna cable thru a grommet, then sealed that up with some black rtv:
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CB radio is mounted under the seat with an external speaker under there as well. Future plans are to mount the speaker between the head rest posts.
 
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So the obligatory "Specs" post:

Engine:
Completely rebuilt 3VZE 3.0L
LCE EGR Delete
Flame Thrower Injectors
7MGE Supra Volume Air Flow Meter Swap
Custom built silicone/aluminum intake tube w/ AMSOIL dry filter

Suspension:
Front: 1.5" Ball joint spacers
Rear: FJ80 Land Cruiser coils w/ 1" Delrin spacers
Custom Rear Panhard 3" drop bracket
Sky Off Road Adjustable Panhard Bar
Front sway bar removed

Axles:
Front: Stock IFS, 4.88 gears, Spartan Locker
Rear: Stock 4 link, 4.88 gears, Open

Armor:
Custom Front plate bumper
Custom Rear plate bumper w/ tire swing out
Custom Front diff, Trans and X-Fer Case 1/4" plate skids
SOS Off Road Sliders (Welded On)
Blue Torch Fab Rear Diff Armor

Recovery:
Smittybilt XRC8 w/ relocated solenoid into the engine bay and in-cab controls
7/16" Synthetic line and MasterPull Solid Thimble

Comm/Nav:
Cobra 75WXST w/ Wilson 1000 antenna
Yeasu Dual Band 7900 w/ Comet Antenna
LG G Pad 7, running Backcountry Navigator; on a Ram Mount floor mounted arm

Interior:
Paranoid Fab 6 Switch panel below radio
Rear Cargo Deck w/ drawers and sleeping platform

Lighting:
Cargo and Dome light LED replacements
Rock lights: 12ea Eagle Eye 9W LEDs; 2ea Lifetime LED 2.5" pods
Back-up Lights: Rigid Industries Diffused Pod LEDs
Fog lights: Sidetracked Off Road 18W Spot T6 Pods

Oils/greases: Everything is AMSOIL

Upcoming Mods:
Custom Roof Rack
 
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Getting rid of some chrome
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Grill, door handles, mirrors and rear bumper all blacked out.
Only things left with chrome are the windshield trim and the pwr antenna tip.


Next project: Carpentry
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Pic of my custom bedside decals
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These were made by a guy from Tacoma World... he does great custom work.
The B-1B silhouette on the compass is a little personal touch to represent my 21 years (and still counting) in the US Air Force where I started as a B-1 Crew Chief.
 
Great build. Did you use Bedliner for the rear bumper too?

Yep, the same bedliner spray that I used one the front bumper, Rustoleum Truck Bed Liner.

Edit: It goes on really easy, as long as you keep a good distance from the piece and keep moving.
Be advised, it does produce a ton of overspray, so mask off extra wide.
 
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Looking good.
I enjoy adult beverages and working on vehicles as well haha

Wow, whiskey wrenching. You don't **** around.
I was thinking the same thing ^^^... few too many of those and this truck would still be in pieces all over the garage floor.

Your truck looks KILLER! That lift is perfect! Love it!

Thank you! I'm quite happy with the way the lift turned out. Did a ton of research here and on YT, was nervous about doing the LC springs but finally just ordered the springs and went for it. The rear springs were pretty cheap too less than $50!!
 
7MGE Air Volume Meter Conversion

I did an air flow meter conversion from a 7MGE (Supra)... the air inlet is much larger giving this 3.0 some extra air to breath.
BIG difference!! I saw a big gain in off idle throttle response and a definite power increase. Paired with a decent exhaust (future plans) should be a great match; these will likely be my only performance mods.
All details for the swap are located here on YotaTech -- no sense in recreating the write up.

Before the swap:
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Making room:
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After the install:
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I went nice with 3" silicone couplers and aluminum tubing from siliconeintakes.com
Still have some tuning tweaking to do but so far extremely satisfied with this mod!

Also made some room down there to relocate my winch solenoid, probably the next mod. :D
 
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