Dynamite Design - Tacoma T-Rex

[MetalCraftSolved]

Something that started as a simple Dana 60 shave, has turned into a full on build. Josh Chappell has shown up ready to pull a 180 on his Tacoma project. He picked it up from a guy down in the Bayou'. There has been a mess of fabrication done on this rig from the previous owner. Josh got the rig on a deal and his plan has been to basically redo everything as good as it gets....

Since, and long story short.... Josh has joined Dynamite Design and is committed to moving forward. You'll meet him very soon.

Let's build a Tacoma T-Rex

 

[stinkbomb]

Could we get more pics of that brake?

 

[dkrajcovic]

sweet

 

[pcole0920]

Looks great david. Need to swing by and check it out

 

[Dynamite Design Josh]

Seeing as how David has already introduced me I will jump right in to this build thread with my contributions. As he has already stated I have joined the Dynamite Design team and both of us are prepared to move forward aggressively with several products. On to the build.
I purchased this truck off the forums from a gent near New Orleans. I knew it had problems. I did due diligence prior to the purchase and had found the previous owners build threads. I knew what I was getting in to and it was a hell of a mess. but at a price of $7500.00 with only 70k on the odometer it was exactly what I was looking for. This first group of pictures show the truck in pretty much the state it was in when I brought it home. It only serves to give every one a base line… and to remind David and I of how far it has come.

 

[Dynamite Design Josh]

At some point during my parts gathering phase and while I was building my axels I decided to shave my front and rear Dana 60, which were both purchased from NC4x4 members. I was pointed to David Guest by another member on here. David swung by the house one evening and picked up the axels and a week later I went over to pick them up. David and I hit it off immediately and quickly realized that together we had a good combination of skills and assets. The rest is a long boring story that maybe one day we will share around a camp fire after a day of wheeling.


the start to my pile of parts

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the axels

[URL=http://s1219.photobucket.com/user/priest0321/media/TIGedplates_zps89759453.jpg.html]
Shave Kits TIG'ed on[/URL]

 

[NCrunner4x4]

Seen this truck on other forums, look forward to the transformation.

 

[Dynamite Design Josh]

This is the Day the truck rolled into David's shop. As you can tell I had all ready fixed the body and added fiberglass fenders and bed sides.
Tear down was very fast. Neither of us had much mercy for the old stuff




Tranny prepped for inchworm taco box and FJ Cruiser manual case to be installed.


front tore out










mess all cleaned up ready to get to work

 

[Dynamite Design Josh]

Crawler in the original position. Neither of us liked how low it was so it was clocked about 15*



The crawler is just a standard Inchworm Taco box with 4.7:1 gear set and an FJ Crusier automatic T-case behind it. This set up is tried and true in several other 05+ tacoma builds. In addition to the crawler it makes the T-case a manual case with 2h 4H and 4L. It is also modified for short throw twin sticks. It also has a plugged worm gear in it so I can put in a speed sensor and clear the check engine light. This is required on the 05+ Tacomas since we are ditching the ABS and factory axels and with them go the tone rings. Without the speed pick up these engines will not run right.

 

[Dynamite Design Josh]

As you can tell from the base line photos, one of the ugliest parts of the truck and most time consuming to fix is the frame stiffening plates that were added to give rigidity to the front section of the frame and remove the front end crumple zone. David and I discussed several approaches to fixing this. The path we ultimately choose was based on one thing - what will yield the best strength and aesthetics.
The process was basically to plasma out the face of the frame sand it down flush with the top and bottom plates of the frame, put in a new face plate, put on a fish plate and plug weld it a lot to get the strength and rigidity we were looking for.










steering box mount is built into the frame and sleeved so the steering box is strapped on for mock up.
















first layer of steel




front side of the steering box mount


steering box mount mocked up




fish plate on


frame rails are done

 

[Dynamite Design Josh]

At some point we put the new brake master cylinder in. Due to the larger calipers and disc on all four corners we went to a 1 ton T-100 master cylinder. A simple adapter is used between the master cylinder and booster, nothing new there. The pushrod inside the booster had to be extended, and the master cylinder reservoir was modified to feed the clutch.


reservoir modified to accept clutch line




master cylinder modified and assembled


longer pushrod complete (OEM pushrod is pictures as well)

 

[Dynamite Design Josh]

Frame brackets were put on and links were mocked up with PVC until the aluminum links arrived. All the axel brackets were fabricated in house. the frame brackets came from an outside source and will be replaced sooner or later.

 

[Dynamite Design Josh]

A set of bead locks were built and sent out to DJ Powdercoating in Kernersville. David did a tech write up on these. you can find it in the tech section. Tires were mounted and put on the truck so we could flex test it and check for clearances

 

[Dynamite Design Josh]

We have had to relocate the engine bay fuse and relay box due to where the shock towers and coil overs are going. A bracket was built from aluminum to hold the fuse block in its new location

 

[Dynamite Design Josh]

Next a crossmember skid plate was built to support the transmission, crawl box and transfer case. mounts were built to bolt the complete assembly to the frame so that it is easy to drop out and service the drive train should the need arise











you can see the OEM hack modified crossmember in the picture beside ours

 

[Hurley]

is the M12 rotary tool a viable replacement for a dremel? I've got some M12 tools already, but I'm leery about the rotary tool

 

[MetalCraftSolved]

Not sure. We have both kits, and I rarely pick up either one. The air tools is where its at.

 

[Hurley]

Josh likes it

 

[MetalCraftSolved]

Could we get more pics of that brake?

 

[Dynamite Design Josh]

Thank you all for your complements and support, from both of us.
I am not sure if any of you have seen any of the 05+ Tacoma SAS that have been done yet, but I wanted to give you a little insight as to what we are trying to do with this rig. All of the 05+ Tacoma SAS that have been built to date are huge, all of them are sky high and most are running 40s. While that is great for the trail and the few who can afford it, and who have another vehicle to drive on week days, you might as well build a buggy. A truck with a ridiculous frame height and 40s, regardless of who you are is not a feasible daily driver for the masses. The cost of tires alone would kill your wallet. I want a truck that can crawl and be driven back and forth on a daily basis. When I started the research for this project, I found that there are just not a lot of companies even trying to do an SAS much less develop a kit. The only suspension upgrades available for these trucks are simple bolt on spacers and coil over kits, yielding around 3" of lift. With those kits, about $6000 more in parts, and major body modification you can only cram 36" tires in and still have limited wheel travel and weak steering and drive train components. There just are not parts available for this truck. With the venerable 1st, 2nd, and 3rd generation pickups and 4runners becoming impossible to find, people are turning to the Tacoma. Now they are turning to the 05+ Tacoma that is aging as well. From the start I wanted something that didn't exist. I realized very quickly that I was heading down the custom path. Shortly after that, I came to realize that I needed help. That is when I found David and both of us saw the opportunity to make a change in what is out there. While this truck is being built with custom style, I assure you it has been designed from the start as something that can be made into a production product very quickly. As this thing comes together you will see the complexity of what's going on. There are a lot of components being stuffed in between those frame rails and under that crossmember. I am sure every one can appreciate what's going on under this full body rig.

Thanks again

 

[boatedwagon]

looks awesome, no need to explain, from the beginning dynamite has showcased one of a kind, not future production line, keep up the great work

 

[jeepmedic]

Keep up the good work!

 

[MetalCraftSolved]

 

[HGSR]

thats a nice rig

 

[MetalCraftSolved]

Josh has given the go ahead to redo all of the Fab work on the rear of his rig, and build a custom 3 link - cantilever suspension.

Almost everything we build for this front and rear 3 link system is designed to be produced as a kit. After we are done putting in the time of considering all of the variables, we should have one of the most solid 3 link systems for this style truck.

The front shock mounts were mig welded. I had to tig weld a set that is to be shipped to Australia. Now that Josh has seen the tig welded set, he wants the same thing on his rig.

I am going to go ahead and make 4 of our almost universal style shock mounts for this truck. They are stylish enough and versatile enough to use in the rear cantilever system. Also, just plain easy to work with, because you can connect them to the chassis, lots of different ways.