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Old 03-09-2007, 03:34 PM   #1 (permalink)
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Front Range builds a new Toy, from an old Toy, #44

We've been busy around here, and have had a chassis now since April. We've gotten new processes in place, and are now on top of the entire works. So what better to do than build a new rig?!

We're starting with our old 85 EFI truck, Im sure many of you recall. It has sat, been scavenged, started rebuilt etc over the last 3 years.

From previous life
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Old 03-09-2007, 03:41 PM   #2 (permalink)
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As it sat, ride height with 40's.
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Old 03-09-2007, 04:09 PM   #3 (permalink)
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Its last trip out, was bit rough. I blew a 4.88 pinion head in half, and was reminded that spring clamps are a good thing.

This was a 6 leaf pack. The bottom one was broken clean off. Hooked over a rock, and had to back up.
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Old 03-09-2007, 04:12 PM   #4 (permalink)
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A few other tricks were done here. A little bit of tubbing....

FYI, the sheetmetal is up for grabs, PM if youre interested.
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Old 03-09-2007, 04:14 PM   #5 (permalink)
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Just one of the reason the stock mounting of tcase crossmembers is not on our favorites list.
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Old 03-09-2007, 04:17 PM   #6 (permalink)
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This was a standard cab/short bed truck. It was replaced with an extra bed with 9" cut from the front, and 11" from the rear. We moved the gas tank up, had to hammer the top of the tank to do it. However the "horsecollar" xmember barely cleared with the 2" body lift, so this was the solution. The 2 peice crossmember was cut from another frame, fully seam welded together, then notched and plated, and welded in place.
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Old 03-09-2007, 04:21 PM   #7 (permalink)
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Before the cab was installed, the rockers were sut when it was tubbed. The back side was cut out, and the outside panel (normally visible at ~45 degrees). The outside was folded into what was left of the inner ~1/2" and welded back together. This truck was built to be low, and this allowed the sliders to be moved up a few inches, gaining needed clearance at the doors.
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Old 03-09-2007, 04:24 PM   #8 (permalink)
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The 40's didnt like where the battery lived, so one tire got jealous and tried to move in!
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Old 03-09-2007, 04:32 PM   #9 (permalink)
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After we yanked the body, bumpers, wiring, etc, we started mocking up one our our laser cut, IFS Box Mount Kits.

Youll notice on the 2nd pic, the sleeve butts to the outer plate, making it very strong.
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Old 03-09-2007, 04:42 PM   #10 (permalink)
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This hideous cluster I am not dealing with. Its going straight to OffroadSolutions.com I think those guys know yota wiring better than the guys who built it! So off it goes for a stripped down, simple plug-n-play setup.
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Old 03-09-2007, 04:53 PM   #11 (permalink)
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Nice rig. Looking forward to more updates(pics).
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Old 03-09-2007, 04:58 PM   #12 (permalink)
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After we yanked the body, bumpers, wiring, etc, we started mocking up one our our laser cut, IFS Box Mount Kits.
I have a box mount kit from Marlin Crawler that looks similar, except it isn't cut diagonally at the ends. One thing I noticed is that the shape of the plate on the MC setup places the mounting holes at the factory positions when pushed all the way forward to the body mount. Is this also true of your box mount kit?
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Old 03-09-2007, 05:33 PM   #13 (permalink)
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I have a box mount kit from Marlin Crawler that looks similar, except it isn't cut diagonally at the ends. One thing I noticed is that the shape of the plate on the MC setup places the mounting holes at the factory positions when pushed all the way forward to the body mount. Is this also true of your box mount kit?
I placed mine in the same place as Brian did and it's foward of the stock postion. I had to drill new holes. Brian's kit is beefy.

edit: It worked out perfect, my axle is 2.5"-3" foward of stock.

Looking good, keep us updated.
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Old 03-09-2007, 05:59 PM   #14 (permalink)
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I have a box mount kit from Marlin Crawler that looks similar, except it isn't cut diagonally at the ends. One thing I noticed is that the shape of the plate on the MC setup places the mounting holes at the factory positions when pushed all the way forward to the body mount. Is this also true of your box mount kit?
Stomper nailed it. Ours is designed from an 85 runner (wife's old rig) with an IFS box mounted as far forward, and as high up as possible, without cutting the radiator support out. Of course folks have used it as a base, and cut the front for moving the box more forward even.

The angle cuts are for preventing cracks. They face different directions on each end of the different sized plates. This keeps loads spread out, not concentrated for, you guessed it, no cracks.
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Last edited by Brian Ellinger; 03-09-2007 at 06:00 PM.
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Old 03-09-2007, 07:14 PM   #15 (permalink)
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Gotta love the red '85 xtra cabs!


I have one myself..

Now I'm just waiting for my front axle from ya so I can go to Harlan....
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Old 03-12-2007, 11:33 AM   #16 (permalink)
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I liked the old body/bed style. What are you going to do with the new one body-wise? Is that #44 an F-toy SN?

And do the new processes mean your r10 crossmembers will be shipping soon?

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Old 03-12-2007, 11:45 AM   #17 (permalink)
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I liked the old body/bed style. What are you going to do with the new one body-wise? Is that #44 an F-toy SN?

And do the new processes mean your r10 crossmembers will be shipping soon?

i think it is going to be f-toy #44 that he has had for a yaer or so

edit; some how you hit your edit as i quoted you
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Old 03-12-2007, 12:10 PM   #18 (permalink)
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wrong forum fawker ... you going to be in globe?
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Old 03-12-2007, 09:29 PM   #19 (permalink)
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Is there a F Toy being built somewhere in this thread?
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Old 03-12-2007, 10:40 PM   #20 (permalink)
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wrong forum fawker ... you going to be in globe?

Fawk yeah he is. We've got some work to do
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Old 03-13-2007, 06:33 AM   #21 (permalink)
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looks like a good starting base, cant wait to see an update. Btw thanks for the axle. this is Pat in california with the PASSENGER DROP TACOMA front. Its in and i think you nailed the pinion angle on the headThanks!!!!
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Old 03-14-2007, 02:05 PM   #22 (permalink)
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Yes, its going Ftoy. We got a chassis at the 06 Jambo. Its been sitting since.

As for clocked xmembers, in stock, we've been making them for a bit over a year now I think.

Pics coming soon, we're trying to get my 6'2" too-tall-for-the-chassis in there.
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Old 03-14-2007, 02:40 PM   #23 (permalink)
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Brian are you going to trail test it? looking good man.

later tj
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Old 03-14-2007, 03:04 PM   #24 (permalink)
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Brian are you going to trail test it? looking good man.

later tj
Of course! And air test it too...
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Old 03-14-2007, 06:17 PM   #25 (permalink)
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Of course! And air test it too...
Liar!!!!! Only TG tests things.
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