2001 Tundra Access Cab Rebuild (part 1)

I would recommend "button" spot welds.

 

Just scored some KO2’s from an ‘06 Doublecab for $650. For my intended purposes, slightly used KO2’s are perfect. I’m not a huge fan of chunky tires, but I think these look good. Just need to find a set of steelies…

 

You are dedicated! I applaud you for taking on such a monumental task!

 

Thank you. Honestly it’s the only way I could afford a five-speed Access Cab 4x4. Sort of like making payments on it. When I had the spare cash I paid my welder to do more work. I’m quite pleased with it. Now I just need to find an affordable Four Wheel Drive camper to mount on the back…any leads anyone?

 

In other news, since my Access Cab is licensed, I posted the regular cab for sale and…it’s gone!

 

It's been quite some time since I last updated, you know how life can get in the way of things. Even if I've been lax in posting, that doesn't mean work on the Tundra hasn't progressed!

Looking back on my last post, it seems like I had just picked up some gentle used KO2's and had tossed them on with the wheels they came with. I've since had them remounted on black steelies (I don't know why I prefer that look, I just do!) and they look pretty damn awesome, even if I do say so myself.



I also scored some front fender flares (the bed from Alabama has a set on them). I plan on painting them (or Rhino-Lining, or something else to protect them) so I didn't care what color they were. Unfortunately, during a particularly heavy rain/wind storm one day while driving home, they both came off never to be seen again. Oh, well. At least I had the chance to take the Tundra out on the beach several times in the fall!





One day last fall I decided to take a closer look at the rear bumper. Oh, brother, it was worse than I had feared. I sourced a solid replacement rear bumper (well, as solid as I was going to find for $50 in New England), but I knew I was going to need something more substantial for my plans. The replacement bumper at least helped me pass inspection The $50 also came with a brand new rear mounting frame which I thought I need, but alas I don't. If anyone out there wants it, hit me up.

In a few of the photos above you can see the square-tube rear bumper my welder fabricated for me. I don't have any photos of that process, but you'll see more of it as I make additions and adjustments.



Speaking of inspections...I had sourced a good Imperial Mica Jade drivers side door to swap out the original one. The glass had come off the track (only after getting into some work on the guts of a door later did I realize that part of the issue was the top bolt that holds the track in place coming loose and tearing the sheetmetal around it). No problem, though, right? Just swap the doors...of course, doing that alone is hard work, as they're pretty damn heavy. I managed to get the door in, and went to connect the wiring harness.

Surprise, surprise. 2001 and 2004 wiring harnesses are just different enough that while the physical actual plugs will connect, the wiring is in different locations. So, while the door glass was raised up and sealed tight, most of the other electrical things didn't work (locks, windows, etc). Fine, whatever, I can get it inspected. WRONG! The drivers side window had to go up and down. Back to my shop, swap the door back, and rush back to the inspection garage to get a sticker before 5pm. Of all the things they could have dinged me on with this rusty heap, that was it? Frustrated by the door mess, I left the original door and taped the window shut. I drove it like that for most of the winter and spring, tired of heaving around the doors and just waiting for a good '01 Imperial Mica Jade to pop up on CL or FB Marketplace. I had an inspection sticker and I was legal to drive! If anyone wants a solid '04 door, hit me up also. I'll never use it.



That brings me to spring 2025, and I'll detail everything I've done since then in my next post.