Ultimate Taco - Part Tres

On the front suspension, shop foreman, head fabricator, and generally grumpy bossman Rob Bonney gave us a quick lesson in fabricating with tube. This support bar was first marked to length with the correct angle. Next, the tube is cut to angle and length with a chop saw.

To get a clean tight fit, the tube is then coped with this coping belt sander. The tube is clamped into a small vise, which can be set to the desired angle and then driven into the round end of the belt.

When the tubes and the front hoops are welded in, the frame is first reinforced since the factory material isn't very beefy, and this spreads out the load from the front shocks.

On the rear of the truck we needed a strong bumper that could take some abuse but still have that race look. Plus we needed one that would work as a crossmember since the stock version was removed. This 2x4 rectangular tube with sleeved speed holes should do the job.

With all the stock brakes gone, and the ABS tossed out in the yard for the dogs to play with, we needed a way to balance the front and rear discs. This proportioning valve from Poly Performance is protected inside the rear framerail and will allow us to give the rear just slightly less grab than the front.

The rear brake lines will run down the Panhard bar and then split across the axlehousing, while the front brakes drop down to the top of the differential and then split out the tube.

To mount the bed sides, the 4Wheelers crew first bolted the fronts to the cab and then built brackets to attach the rear to the bed cage. We decided to dovetail the back in towards the frame so that only the tires stuck out from the frame at the rear bumper. This should protect those valuable sponsors' stickers and taillights, and though not exactly legal, we've got a plan to make it so.

About this time, Clifton Slay from Poison Spyder Customs showed up with his new Tacoma bumper. The stock turn-signal lights pop into the 1/4-inch-thick bumper and will plug back into the original wiring harness.

The truck really started to come together as we installed the PSC front bumper, and the fiberglass fenders and supercharger hood from Kartek. The bumper houses Warn's new 9.5XP winch with the fastest line speed under load of any Warn winch so far. The solenoid box and control switch will eventually be wired inside of the truck for easy access and to keep as much airflow to the radiator as possible above the winch.