Local Legend Project: Tur-BRO-yota

[Turboyota]

Passenger side footwell tubbing complete.

I was able to squeeze both wire harnesses through a single grommet (originally there were two wire looms exiting the passenger-side footwell).

Stock Toyota firewall sheet metal is 22 gauge (0.030"), and it is a challenge to weld. All the sheet metal I added is 18 gauge (0.048").

 

[Turboyota]

Shock mount fab. MagBase Drill for the motherfucking win. Drilling holes with 1.5 1.75 2.5 & 3.25" hole saws in 0.190” 4130 plate with ease.

Time for the plasma cutter.

 

[Turboyota]

Plasma cutting complete. Shock mounts need some tuning on the disc sander, but they fit fairly well as-is. 1/2" shock mount holes will be drilled later.

 

[Turboyota]

Tuning up the upper shock mounts:

Fit check:

More tuning & getting ready to mark & drill holes. Dykem spray for layout:

Making 1.5" Spacers for shock mounts

Tacked spacers in:

Getting ready to plate inside the go-fast cutout. I'm going to cut the tube where it is tangent to the straights and plate the rest with 1/8" 4130. Weld washers are 1/8" waterjet 4130 plate.

 

[Turboyota]

Go-fast closeout coming together:

Bump forming go-fast closeout with the vise brake. I have a throbbing hard-on for that tool.

And everything fitted ready for welding:

 

[Turboyota]

First side getting the mag base treatment:

And complete:

 

[Turboyota]

Tacked passenger side shock mount plates together and mag drilled back side so everything would line up nicely. I had to turn down the back of the carbide tipped hole saw because it was larger than the cutting diameter... what the hell?

 

[Turboyota]

Ready for weld on passenger side shock mount.

I was telling myself last night that "a mig welded truck in the dezert is better than a tig welded truck in the shop..."

Ahhhhhh Fuck it. I'm going to Tig weld the shock mounts anyway.

 

[Turboyota]

Used vise brake to bump more plates for upper shock mount.

And reamed shock bolt holes.

 

[Turboyota]

Side plates are 3/16" 4130 plate.

All the go-fast closeouts are 1/8" 4130 plate

The go-fast pocket radius closeout pieces are 1.75x0.120" wall 4130 tube

Both shock mounts almost fully welded. I'll weld the top closeouts on the truck.

 

[Turboyota]

Fit check after bench-welding:

Total time into the shock mounts thus far: 16 hours

There is around 6 feet of Tig weld per shock mount at this point. Finished it'll be around 8.5 feet per side.

Cost: 0.190" 4130 plate is expensive. I used some of the leftover from the BROmanian's 4 seat Class 1 project, so it was a freebie. I had the 1/8" 4130 chromoly plate.

 

[Turboyota]

Full bump

 

[Turboyota]

Final welds & weld washers... its not exactly weld porn, more like plumper amateur casting couch (weld) porn that hasn't had the razor burn & stretch marks airbrushed off...

And the final bump-formed closeout plate:

 

[Turboyota]

Driver's side supporting its own weight.

 

[Turboyota]

Upper shock mounts: 15 lbs total

Cut off the stock upper shock mount, droop stops, and bumpstop strike on the passenger side.

Total time with plasma and grinder: 0.5hrs
Weight removed: 3 lbs

Tacked upper shock mount on and it was apparent that I'd need resi hose clearance. On the inside, the hose was crashing against the intake manifold. On the outside, the hose crashed against the lateral plating on the shock mount.

So I took the resi off: Sway-a-ways require heat for reservoir removal.

Checked fitment:
Installed a hydraulic fitting from my stash.
No fit even with 37deg-3/8NPT to compact Eaton hydraulic 90. Damn.

I clearanced the 1/8" plate: carbide-tipped Holesaw used in the Ryobi 1/2" drill

Cut out the web with 4.5" grinder & cutoff wheel:

Now it fits:

 

[theycallmeWALLY]

Your documenting skills are next level.

So crazy how much work goes into every little thing to make these trucks 'go fast' and stay together.

Thanks for sharing

 

[Turboyota]

I used the vise brake to make this frame doubler plate that wraps the front and back side of the frame. I dropped it down the back side of the frame to make it easier to weld.

I made this awesome mockup tube for the front of the passenger side shock mount:

Once I had the fitment dialed on the mockup tube, I de-rusted a piece of 1.5x0.120" 4130 in the lathe with 220 grit. Now it looks like shiny welded seam BRO tube:

Copying the mockup tube; the rear passenger shock mount brace is fully tiggered up on the bench.

Fore & aft shock mount braces:

The shock mount brace tubes are not mirrored about the center of the motor--driver vs passenger side are significantly different. Throttle cable and intake manifold clearance has been a challenge on the passenger side.

 

[Turboyota]

Driver's side shock mount brace tubes fully tig welded to the frame:

 

[Turboyota]

Finishing the passenger side upper shock mount and support tubes involved a significant amount of Tig pedal kegels.

Here are the materials & quantities I used on the support tubes:

6.5 ft of 1.5x0.120" 4130

Qty 2: 1/8" 4130 egg-shaped frame gusset plates

Qty 1: 1/8" 4130 c-channel shaped frame gusset plate

Qty 5: ground tungsten electrodes

Qty 6: 1/16 er70s-2 filler rods

 

[Turboyota]

Grille mounted and the hood and fender mounts tacked together.

I made some little tabs with 2X 1/4" holes each to mount the grill.

Top plate is 16 gauge hot rolled, and the front vertical gusset is 1/8x1" bar. Go-fast dimple die has a 1.5" hole and flares out to around 2".