Rebuilding an '85 Toyota Pickup

[Brucker]

Being new around here I thought I would post the re-build of my little '85 Toyota Pickup. You can find a couple different build threads on a couple different forums but thought this might be a good way for you all to get to know me a little better. I "finished" it a little over a year ago. Since then I have been making more modifications and updates as time permits. It may seem like I am flying through some of it pretty quickly, and I will be, but please feel free to ask me any questions, or ask me to go into greater detail about anything. I also don't mind any constructive criticism you may have to offer, so bring it on. Hope you all enjoy!




I bought this '85 Toyota from a fellow wheeler off another board a while back that I was planning on using for parts. The thing already had a lift, was running 35's, sported some tubework (bumpers and sliders), was geared, and the rear even had a locker. But it was a basket case. The rust had destroyed the bed and even most of the rear shackles. It was used and abused and was begging to be parted out. But as I got to looking at it more closely, I thought it would be worth bringing it back from the disrepair it was in. I sat down and mapped out a plan for the build. Wanted something on a budget, that could be used to run around town picking up parts and also keep up on the trails.

Before:





The plan:

Budget Build
Keep lightweight yet durable
Keep leaf sprung
Maybe keep sliders
Maybe keep front bumper
Keep drivetrain but add doubler (dual transfer cases) - for now, but really want EFI
Add front locker
Ditch bed for tube work
Update interior
New Paint
Max of 37" tire
Maybe a better stereo
Maybe upgrading the seats to a suspension seat with 4 points


With a good plan of attack mapped out, I put the old girl under the knife. I thought we should ditch the bed in favor of a tube one. I also wanted to cut off the rear bumper it had welded on, so we could shorten the length of the frame. So off came the bed and the rear part of the frame and bumper with the help of an overhead electric shop crane:



With the bed and bumper off it was time for a little clean up and more tear down. We stripped the doors, fenders, hood, grill, interior, and most of the suspensions off. With more working room, I started on the rear tube work.





Made a new rear cross member/bumper that will hold the lights and a receiver hitch. Decided I wanted to run my hitch receiver mounted winch on this project. This way I will be able to run a winch off the front or the rear, with a little bit of wiring. Rear came out ok I thought. Still need to mill holes for the reverse lights though.



Got the rear welded in and a few more sections of tube welded in.

[Brucker]

Made a shelf to hold a steel tool box, and a mount for a pivoting rack to hold my spare tire. And yes I made the pivots grease-able.





Then I started mock up of a one piece, bolt-on rear fender.





Not sure if I dig the fender mock up. Might end up just flat paneling the side of the tube. But I do want something to help keep mud/dirt from flying all over the gear in the back. Decisions, decisions.

I then got the rear tube work fully welded (except to the frame). Decided it would be a good time to paint the cab before the tube work got in our way. So we cut off the rear tube work of the frame and removed it using the electric hoist again.



Then started prepping the loose panels for paint, as well as the cab, inside and out.





I was then able to coat everything in primer.

[Brucker]

I let my wife choose the color for this project as I was undecided. What she picked turned out to be pretty bright.





Once the paint had set up, I got to work coating the interior. I choose to use Herculiner. I have used it extensively in the past and really like the performance I received out of it in interior applications. I was happy with the outcome once again. You will notice that I also cut a hole in the floor for the second transfer case shifter.

[Brucker]

Got the dual cases assembled and quickly coated.



I then decided it needed a T-case e-brake, so I got one put on.



I had already cut a hole in the floor for the new shifter before I coated everything so I then used a mount from TG and got everything bolted back together. And I also connected the factory e-brake cable to the linkage of the transfer case brake.



Then I was able to reassemble the entire interior including the seats that came with it, which are out of a Honda I believe.

[Brucker]

Wired the truck front and rear with quick connects for a receiver mounted winch. Seems like the cheapest, fastest solution since the existing bumpers both have a receiver hitch.





Welded on the lockable steel tool box, and made a mount for a 60" Hi Lift jack on the rear tube work.



Then prepped, primed, and painted the assembly before welding it into place on the truck.

[Brucker]

Not liking the stock location of the gas tank, as well as not really appreciating the strength of it and the stock skid, I made the decision to build a custom cell. I would locate the new fuel cell behind the rear axle and in front of the rear bumper/crossmember, up high and tight between the frame rails. This will allow for better overall clearances and leave more room in the bed for gear, supplies, and spares.

-I have to apologize here as some photos have been lost-

I fabricated the baffled fuel cell out of stainless, while using a 1/4" thick plate on the bottom side of it to act as a built in skid. It uses the stock float and sending unit so the dash gauge should still function. I positioned the new fuel cell in it's approximate new location with a floor transmission jack so I could design and fab up some mounting brackets. Then did so and welded them into place. I will use poly swaybar bushing between the cell mounting points and the frame mounting points to help isolate it.





Also fabbed up a couple triangulated shock mounts for the rear.



The truck already had 5.29's in the diffs and had a Detroit in the rear, so I took the rear 3rd w/the Detroit and put it in the front, and then welded the open carrier and threw it in the rear. Please don't mind the blue dust on everything on a few of the photos. Someone thought it would be a good idea to clean up and blow out the area in the shop where we had wet sanded while I was working...



Open carrier:



And now with a little filler

[Brucker]

Fabricated a "bed" floor, or fuel cell cover, however you want to look at it. Still need to cut fuel filler hole and herculine it, but close.





One with the rack folded down:



Then took it outside to see how the rear flexed. Really bright in the sunlight!



I really don't like the shackle angle in the rear. And as I suspected it didn't flex well at. Guess a set of Chevy 63's are in it's future...



Front stuffs nice though

[RidgeRunner]

HaHa, I've been watching your progress over on CO4x4. That used to be my truck, I sold it to a guy up near Loveland back in 2006. I really like what you've done with it.

[Jackie]

RidgeRunner previously posted:

[Patrolman]

Nice build! Looks clean compared to my junk.

[Brad]

Creepy that the color is very similar to Josh (Haku) yota.

[Brucker]

RidgeRunner previously posted:

[Brucker]

To attach the rear bed floor/fuel cell cover I used cage nuts welded to angle iron that I punched holes in and stainless buttonhead bolts to fasten through the panel to the rig.

Here are the cage nuts:





spot welded to the angle:



I welded the angle near the corners of the frame and attached the panel. Not a great photo, but you should be able to notice the SS buttonheads in the corners.



Then I moved on to the rear suspension. As I suspected, the rear just didn't flex well at all. So time to swap out the existing rear leaf springs for some Chevy 63's. And while I was at it, new spring/shackle hangars, shackles, and some U-bolt eliminators.

Spring hangers:



Shackle hangars:



U-Bolt eliminators:



Stance with the new shackles and Chevy springs installed. Check out how much better of a shackle angle I was able to give it, and how flat I was able to keep the leafs. Only real downside is how far out the shackles stick from the rear bumper/cross member. Although, I need to remember it is still WAY better than stock since the frame was shortened and the bed taken off.

[Brucker]

Moment of truth as the time has come to see if my modifications to the rear suspension helped at all.

Hooray, success! Flexes mucho better:

[Brucker]

Brad previously posted:

[glacierpaul]

Really nice build Aaron!! Great looking work!!

[xaza]

Very nice build. I think wife did a great job picking the color. Very nice flex.

[Java]

Awesome build! It is a popular color, here's my old 81 with it.

[Fordguy77]

Awesome build. It always puzzles me how every one else has these awesome facility's to work on the rigs! Then there's me with multiple projects at multiple locations. Spend more time in transit than I do wrenching.
rig looks great! Keep up the good work!

[Funrover]

Awesome build!