Hub/Spindle/Brake RebuildHere the coil-over is shown installed with the reservoir mounted to the shock-hoop. We painted the brake calipers and installed new rotors, pads, wheel bearings and seals; figuring that it was good time to address those things since we already had the front end torn apart. The total cost was about $150. Extended-length DOT-approved flexible stainless-steel brake lines are included with the kit. We installed and bled them when we reassembled the hubs and spindles.Hub/Spindle/Brake Rebuild Here the coil-over is shown installed with the reservoir mount Fiberglass FendersFlared fiberglass fenders need to be installed to provide coverage for the additional track width of the Total Chaos Caddy Kit. We ordered a set of fenders from Glassworks Unlimited because we really like the squared lines of their fenders for these older Toyota trucks and we have been pleased with the quality of their products in the past. First we removed the turn signal screws and then the bolts along the hood seam. The last few bolts are only accessible when the doors are opened.Fiberglass Fenders Flared fiberglass fenders need to be installed to provide coverage fo We didn't see any point in keeping this stock fender-mount, which is now behind the enlarged wheel-well opening.We didn't see any point in keeping this stock fender-mount, which is now behind the enlarg So we decided to relocate the stock front lower mounting point to gain additional tire clearance, trimming the fiberglass fenders before installing them.So we decided to relocate the stock front lower mounting point to gain additional tire cle We lined up the flared fiberglass fenders, drawing intersecting lines at the center of each of the four fender-mounting holes inside the engine compartment. We drilled the holes and then bolted the new fenders onto the truck using the factory hardware, including the rubber hood-bumpers.We lined up the flared fiberglass fenders, drawing intersecting lines at the center of eac Three holes needed to be drilled through the fender to fasten it to the turn signal mount. Rivets secure the fiberglass fender to the steel turn-signal mount.Three holes needed to be drilled through the fender to fasten it to the turn signal mount. With the fender loosely installed, we adjusted them for fit. Notice how well everything lines up (without any bodywork). Aside from starting with high-quality parts, the key to making fiberglass body panels fit well is spending the extra time that it takes to do the job right.With the fender loosely installed, we adjusted them for fit. Notice how well everything li The Caddy Kit is designed to clear 33" tires at full compression and from lock-to-lock steering. We hammered the pinch-weld at the firewall flat against the body as an added precaution to ensure that the tire doesn't contact the body on full compression.The Caddy Kit is designed to clear 33" tires at full compression and from lock-to-lock ste We trimmed the mounting tabs for the inner fender skirts and removed the excess material, as shown in the second picture above. The third picture shows the prepped pinch-weld ready to be folded flat.We trimmed the mounting tabs for the inner fender skirts and removed the excess material, We laid down a thick bead of silicone along the inside edge of the pinch-weld seam where it was going to be folded over.We laid down a thick bead of silicone along the inside edge of the pinch-weld seam where i Using either a large ball-peen hammer or a small sledge, hammer the pinch-weld down flat. Once the silicone has dried, spray a coat of paint on the exposed metal edge.Using either a large ball-peen hammer or a small sledge, hammer the pinch-weld down flat. Wheel/Tire SelectionWe chose to use 33x10.5-inch BFG Mud Terrain tires, mounted on 15x8-inch forged aluminum wheels from Alcoa with 4.5 inches of backspacing. This is absolutely our favorite tire size for compact IFS pickups. These 10.5-inch wide tires are noticeably lighter than 33x12.5-inch tires. The reduced un-sprung weight improves acceleration, braking and handling without compromising traction off-road. Completed InstallationThe Total Chaos coil-over Caddy Kit is just as expensive and almost as time-consuming to install as a properly done straight-axle conversion, but this is not a second-rate upgrade. Our completed 4Runner only sits 3 inches higher and 6.5 inches wider than stock, cycles 12 inches of vertical wheel-travel and clears 33-inch tires. Our initial impression is that we're going to enjoy the improved ride-quality, handling and all-around performance of this versatile setup. We're planning to install a pair of Deaver leaf-springs in the rear along with a pair of 2.5x12" remote reservoir Sway-A-Way Racerunner shocks and then enjoying the drive on our way to the trail. SOURCES Alcoa www.alcoawheels.com Swayaway www.swayaway.com Off Road Warehouse www.offroadwarehouse.com Trails Less Traveled www.trailslesstraveled.com Total Chaos www.chaosfab.com Eibach Springs 17817 Gillette Ave. Irvine CA 92614 959-752-6700 www.eibach.com BF Goodrich Tires 877-788-8899 www.bfgoodrichtires.com Glassworks Unlimited www.glassworksunlimited.com « | 1 | 2 | 3 | 4 | View Full Article By Sean Estes Enjoyed this Post? Subscribe to our RSS Feed, or use your favorite social media to recommend us to friends and colleagues!
