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Cabin Fever 05 DC "build"

Discussion in '1st Gen Builds (2000-2006)' started by Cassiooohh, Apr 16, 2020.

  1. Apr 16, 2020 at 8:32 AM
    #1
    Cassiooohh

    Cassiooohh [OP] New Member

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    I'm very fortunate to be able to continue working from home during this time. However this is usually around the time I start thinking about summer time in Colorado. As an educator with summers off and an avid fly angler summer is the time for my annual pilgrimage from San Antonio, Texas to the Rocky Mountains. This thread will document the build up of my 2005 Tundra as my daily driver adventure mobile. But lets go back a couple years...

    After a few memorable trips in my Volvo awd wagon it was time for something more capable and reliable. Toyota 4x4 it had to be.

    I considered a Tacoma, I had a 1st gen pre runner in the past and really enjoyed the truck. However some major factors steered me towards a 1st gen Tundra. First was cost; same year, mileage and features the tundra often sells for less. Power; one of the things I remembered about my stock Tacoma was that it felt under powered (should have gotten a manual trans). I knew with the hopes of a boat in my future I wanted more. Cabin size; for long drives both in my own and in friend's Tacomas I just felt cramped. One of the biggest factor however was the ability to sleep in the bed. At 6'3" tall not many modern trucks allow me to sleep in the bed.

    The Tundra met all these requirements and then some. The hunt began, I looked for over 5 months for what I was looking for: 05-06 Dbl Cab, 4x4, Tow package with LSD, Leather but no sun roof, no modifications, maintenance records, no accidents, one owner, no rust, under 150k miles, and it couldn't be black. Okay maybe I was a little picky but it paid off! Found one only 4hrs away!

    The dealer add had no photos, a salesman sent me these photos. After verifying some info I took off a couple days later to pick up my new truck.
    [​IMG]
    [​IMG]
     
  2. Apr 16, 2020 at 8:42 AM
    #2
    Cassiooohh

    Cassiooohh [OP] New Member

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    This truck was everything I was looking for and the dealership gave me a great deal on my Volvo as a trade in. One of the biggest selling points, one owner truck with intensive maintenance records. I'm not exaggerating on the records...
    [​IMG]

    Still took care of replacing all fluids with appropriate synthetics, replaced master cylinder, pads and rotors. Cleaned, adjusted and greased drum brakes. Used OE Toyota parts.
     
  3. Apr 16, 2020 at 8:42 AM
    #3
    FirstGenVol

    FirstGenVol Brake Czar

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    Sweet find! That's a great color and the matching cap is a score. You checked the frame for rust I assume? That's really the biggest concern with these trucks.

    What mods will you do first?

    edit-wow! That's an amazing maintenance log.
     
  4. Apr 16, 2020 at 8:46 AM
    #4
    Cassiooohh

    Cassiooohh [OP] New Member

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    Yep cap was a plus, and og owner had bed liner done (receipts still in glove box). Not only is the truck completely rust free (was in Austin and west Texas its whole life) the og owner took it in and had the dealership verified during the recall.
     
  5. Apr 16, 2020 at 9:02 AM
    #5
    Cassiooohh

    Cassiooohh [OP] New Member

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    First mod was removing those god awful side steps! I'm tall, all they did was stick out and get my pants dirty when getting in to the truck. One beer later they were off and sold to someone else by the end of the day. :amen:

    Next was the Thule roof rack install onto the cap. I have no photos of the process but lets just say it was stressful drilling 12 holes into your new truck. 5 beers later it turned out great and on went my Rod Vault. Holds 3 fly rods all strung up and ready to go.

    Finally some quick measurements and a trip to Home Depot had a platform built in the bed. A quality inflatable mattress fits perfect with room to spare.

    The truck was ready for its first trip up to the mountains!
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
  6. Apr 16, 2020 at 9:28 AM
    #6
    Cassiooohh

    Cassiooohh [OP] New Member

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    Whats next?....

    $1200 was recently deposited into my account yesterday. Tires and shocks ordered.

    Suspension
    I did my due diligence and researched all my options. Went back and forth and had many considerations. In the end I just couldn't justify anything beyond 5100's. Almost pulled the trigger on the 6112's. However reliability and drive ability on long road trips was my focus and the 5100's will get the job done. The front of my truck is 1.5" lower than the rear, even with the cap. I'll set the shocks on the middle setting get the 1.07" I'm after to level it (with a slight rake) and not stress anything else in the suspension or steering.

    With just a 1" lift can anyone justify a diff drop or cv boot mod?

    Tires
    Two words, PIZZA CUTTERS! I ordered Falken Wildpeak at3W in 255/80r17. Why? I did not want to sacrifice as mentioned before reliability or drive ability. The extra weight and size of 285 just had more cons for me than pros. The 255 on stock wheels will just maintain far less stress on suspension and steering components. To me not having a part fail in the middle of nowhere far out weights any possible benefit of the wider tire. Plus I'm in the camp that I think the skinnier tire looks actually more rugged and believe it will outperform a wider tire in the situations I will typically be in.
     
    Darkness likes this.
  7. Apr 16, 2020 at 9:32 AM
    #7
    FirstGenVol

    FirstGenVol Brake Czar

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    I wouldn't mess with a diff drop if you're only going up 1". I lifted the front of my truck 2" and I didn't do a diff drop, my CV's are still at an acceptable angle.
     
  8. Apr 16, 2020 at 10:00 AM
    #8
    Cassiooohh

    Cassiooohh [OP] New Member

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    This was my thought. I'll put the money savings towards new LBJ's, might as well do that along with the shocks. I'll eventually pick up some SPC upper arms to just replace the whole assembly at once.
     
  9. Apr 17, 2020 at 8:58 AM
    #9
    Cassiooohh

    Cassiooohh [OP] New Member

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    Thanks to @speedtre I got the right part number for the lower ball joint kit. (04006-62134) Found it locally but ended up ordering online from a dealership for $195 shipped. 2 ball joint, castle nuts, and new cotter pins (maybe new bolts).

    So in route:
    5100 shocks
    kyb strut mounts
    OEM LBJ's
    extended ratcheting wrench for rear shocks

    Tires will get here today. Got really excited this morning when I heard a truck out front but it was the garbage men.

    In the mean time I took care of some other needed maintenance. I replaced the broken tail gate latch last month. Any advice on adjustments to get the tail gate to open easier? Even with everything greased and and latch on I still have to play with it or apply pressure to the tailgate for it to open. I also noticed a bad cable so I took care of that today.
    [​IMG]

    Also inspected the rear axle seal leak I had noticed recently. One of the possible causes was a clogged breather, so at the time I replaced it and extended it to the taillight. I'm keeping my fingers crossed :fingerscrossed: that now that the pressure has somewhere to go the small leak will stop. I cleaned up the drums, drained and replaced diff fluid at the proper level. So far I don't see any wetness on the outside of the drum. I'll inspect the inside when I install the shocks.
    [​IMG]
    [​IMG]

    Next post, new tires :yes:
     
    speedtre likes this.
  10. Apr 19, 2020 at 10:34 AM
    #10
    Cassiooohh

    Cassiooohh [OP] New Member

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    So here's the skinny on the new tires!

    I missed a $100 off deal by a day but the salesman at Discount tire Direct was able to knock off $15 each tire. Had the Falken's shipped to my door for $768. To sweeten the deal even more I sold my used Michelin's for $200 the next day!

    Once again these are in the 255/80r17 size. Below I have it next to my 265/70r17 Michelin (both tires unmounted)
    [​IMG]

    Once mounted and aired up they filled out nicely, giving the wheels plenty of protection. They are definitely skinny but don't look out of place by any means. Gives it that utilitarian look I was hopping for. The true 33" height really filled the the wheel wells, even at stock height it looks great.
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]
     
    Dannydirtyfingers likes this.
  11. Apr 19, 2020 at 3:40 PM
    #11
    Lupe

    Lupe New Member

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    Is this.... my truck...? Lol jk great color choice lmao. This one is mines.

    20200321_072041.jpg
     
    Darkness likes this.
  12. Apr 20, 2020 at 10:12 AM
    #12
    Cassiooohh

    Cassiooohh [OP] New Member

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    :cheers: Twins!
     
    Lupe[QUOTED] likes this.
  13. Apr 20, 2020 at 11:57 AM
    #13
    Lupe

    Lupe New Member

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    Yea my grill and mirror cap are red but i think i like yours better how that chrome gives it a different look
     
  14. Apr 27, 2020 at 7:39 AM
    #14
    Cassiooohh

    Cassiooohh [OP] New Member

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    Still waiting on the KYB top hats to install the 5100's. In the mean time I got the rear deck and storage all finished up!


    This is the basis of the frame. Toyota was smart to engineer the grooves in the bed to perfectly secure 2" wide lumber. With the tail gate closed these are completely secured as is, plus set screws in one of the cross slats for extra insurance.


    [​IMG]

    [​IMG]


    That light pine really stood out against the black bed liner.


    [​IMG]


    Much better!


    [​IMG]


    Next were the drawers. They are pretty shallow, but with a regular topper I wanted to maximize head room. They are still deep enough for your typical under bed storage containers to fit. I added one divider to provide a quick access hatch with out having to pull the drawer out or open the tailgate.


    [​IMG]


    The finished product:


    [​IMG]

    [​IMG]

    [​IMG]


    Now I'm on the hunt for the perfect mattress. Luckily it measures the size of a short queen mattress (75"x60") however I'm looking for something with a more durable and NOT WHITE cover than the typical mattress toppers I'm finding. The Amazon search continues.
     
    imDementeD likes this.
  15. Apr 27, 2020 at 7:53 AM
    #15
    Darkness

    Darkness Allergic to white

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    I can relate to any man who measures job difficulty in the beer scale. Nice progress so far.
     
  16. Apr 27, 2020 at 7:58 AM
    #16
    Damie Street

    Damie Street New Member

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    Sub'd.

    Great build so far bud.
     
  17. Apr 27, 2020 at 10:12 AM
    #17
    Cassiooohh

    Cassiooohh [OP] New Member

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    Its a great standard!

    All parts are in for the 5100 install. Shocks, Kyb mounts, OEM LBJ's and extended length ratcheting wrench for the rear shock bolt. So that should be going on today or tomorrow.
    After some measurements of the rear I also figured an AAL is needed so got the wheelers 3 leaf progressive on order. Oh and also a 12v fridge :thumbsup:
     
  18. Apr 27, 2020 at 11:05 AM
    #18
    Darkness

    Darkness Allergic to white

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    5100 front - 1 beer
    Lower ball joints - 1.5 beer
    Rear add a leaf - 2 beer beer
    Rear shocks - get the whiskey out!
     
    Damie Street likes this.
  19. Apr 27, 2020 at 11:40 AM
    #19
    Cassiooohh

    Cassiooohh [OP] New Member

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    :cheers: Would have been a great time to test out the new 12v fridge, I'll rely on a cooler for now. Time to get to work.
     
    Darkness[QUOTED] likes this.
  20. Apr 28, 2020 at 7:07 PM
    #20
    Cassiooohh

    Cassiooohh [OP] New Member

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    Made some progress on the suspension finally and got the front completely done today.


    5100’s 3rd notch, factory springs

    KYB Top mounts

    Replaced Oem Lower ball joints (old ones still looked like new at 177k?)

    Cleaned speed sensors

    Cleaned and re tighten pinion seal on rack (it’s got a small leak

    Gave everything a nice scrub and wash.


    [​IMG]


    Something always has to go wrong. Luckily this little bolt came right out with a counter drill.


    [​IMG][​IMG]


    Everything torqued and job done.


    [​IMG]


    Gave me exactly a 2” lift and put me right at 22” hub to fender in the front and 21” in the rear. Front should settle down some to where I want. I have Wheelers progressive AAL coming in this week. I think with out the over load spring and the 5100’s in the rear, should sit just right with a slight rake even with the topper and added weight in rear.


    [​IMG][​IMG]
     
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  21. Apr 29, 2020 at 7:24 AM
    #21
    imDementeD

    imDementeD New Member

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    Looking great!

    Got to love the "Something always goes wrong" because that's the damn truth!!!
     
  22. Apr 29, 2020 at 2:52 PM
    #22
    Cassiooohh

    Cassiooohh [OP] New Member

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    Some of the biggest lessons are learned from mistakes.
     
    imDementeD[QUOTED] likes this.
  23. Apr 29, 2020 at 5:11 PM
    #23
    Cassiooohh

    Cassiooohh [OP] New Member

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    Mattress came in. I ordered one to check for fit but quickly ordered a second one. Just what I was looking for, folds up and has a durable washable cover. We’ll see how the foam does over time but at just 3 inches it’s good enough for me. Couldn’t ask for a better fit.


    Here’s where I found it: https://www.amazon.com/American-Furniture-Alliance-TriFold-Mattress/dp/B00CL9900E?th=1&psc=1


    [​IMG][​IMG]


    Also upon inspecting the new suspension I noticed grease coming out of the outer cv on the driver side. During install I did notice some fresh grease leaked out from the inside of the clamp but didn’t think it would continue when back in place. So what now? I think there might be a slight tear on the rubber under the clamp. *searching replacement boots*

    [​IMG]
     
  24. Apr 29, 2020 at 6:02 PM
    #24
    imDementeD

    imDementeD New Member

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  25. Apr 30, 2020 at 7:26 AM
    #25
    Cassiooohh

    Cassiooohh [OP] New Member

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    Here’s a close up of the cv boot leak. You can see the grease squeezing out fbasically under the clamp.


    Think a hose clamp could remedy it? Or a punctured boot that needs to be replaced?


    These boots look like new and were replaced by toyota around 90k miles. My dumbass must have puncture it during the shock install.[​IMG]


    [​IMG]


    On the plus side, the second mattress came in and it’s like I had them custom made. Perfect fit, seems easy to clean, and so far pretty comfortable. Oh and my 12v fridge came in! More on that later.


    [​IMG]
     
    imDementeD likes this.
  26. Apr 30, 2020 at 8:39 AM
    #26
    Kings

    Kings New Member

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    Love the thread. I did something very similar with the bed of my truck for camping, and has worked great on trips 2-4 weeks long. Pictures are from when I was building it. For the mattress I bought those cheap foam pads from Walmart that are about 3" thick. Two of the foam pads side by side exactly fill up the width of the bed.
    0429192002.jpg

    0518192042.jpg
     
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  27. Apr 30, 2020 at 8:45 AM
    #27
    imDementeD

    imDementeD New Member

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    I went ahead and ordered (2) last night. They look perfect for my needs. Hoping to get my drawer setup done this weekend!

     
  28. Apr 30, 2020 at 10:20 AM
    #28
    Cassiooohh

    Cassiooohh [OP] New Member

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    Wish I had the camper, drawers look great!
    Hope they work for you! :fingerscrossed:
     
    imDementeD[QUOTED] likes this.
  29. Jun 1, 2020 at 5:17 PM
    #29
    Chris Barnes

    Chris Barnes New Member

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    Looking good! following along to steal ideas for my new to me 06DC build

    I just scored a shell.. starting to plan camper layiut
     

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