Hub/Spindle/Brake Rebuild...
Hub/Spindle/Brake Rebuild
Here 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.
Fiberglass Fenders Flared...
Fiberglass Fenders
Flared 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.
We didn't see any point in...
We didn't see any point in keeping this stock fender-mount, which is now behind the enlarged wheel-well opening.
So we decided to relocate...
So we decided to relocate the stock front lower mounting point to gain additional tire clearance, trimming the fiberglass fenders before installing them.
We lined up the flared fiberglass...
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.
Three holes needed to be drilled...
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.
With the fender loosely installed,...
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.
The Caddy Kit is designed...
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.
We trimmed the mounting tabs...
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 laid down a thick bead...
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.
Using either a large ball-peen...
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.
Wheel/Tire Selection
We 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 Installation
The 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.