The official Xota build thread

[87xjco]

Xota build-up

This will probably make both Jeep guys and Toyota guys cringe. But, I
rolled my XJ and I have some bucks into the Detroit locker and true trac & 4.56 gears
in the differentials, and since the motor and trans. run real good. I
decided to do this project. I could of picked up another XJ body cheap
but it is hard to get big tires on an XJ and I find myself needing a truck
for hauling often.

I also didn't want to just chop the roof as I want it for cold weather driving.

So my solution is to buy a Toyota cab and frame (found one for $150.00)and use all the XJ
drivetrain and electrical.

Crazy? maybe. Cheap? hopefully.

I'll start with the XJ teardown.

Before the roll
http://i6.photobucket.com/albums/y224/87xjco/xjboulder2.jpg

The XJ was rolled on "Widow maker hill" above Boulder Carnage.
10/2/05
http://i6.photobucket.com/albums/y224/87xjco/Misc/DSC02750.jpg

http://i6.photobucket.com/albums/y224/87xjco/Misc/DSC02747.jpg


Used a sawzall to cut off the roof. I'll need to remove most of the dash to
get out the complete wiring loom and computer. The way the roof was crushed
in it would have been difficult. I will also probably use the console, front
seats, shifters, and who knows what else.

Engine is ready to come out.
10/11/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/10-10rtft.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/10-10lfengout.jpg


Pic's of the Toyota.

It is a 1987 Toyota. Prod. date 4/87. I am cutting off the front frame rails and getting rid of the IFS. I will build my own front frame rails. It did not come with the Toy. rear diff., engine, transmission or transfer, dash and wiring are gone also.
10/15/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC02778.jpg

I test fit the engine in the engine compartment and the I-6 is very long for
this Toyota. It is going to take some work to get it to fit. The painted
outline may end up being a cut line for the firewall to gain clearance.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC02779.jpg

[87xjco]

Started building the front frame rails. The rails are 1/4" wall 2X3.
10/18/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/rails.jpg

Cab is now off and I've started mocking up the Lt. Rail.
10/21/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/Lrailmock.jpg

Setting up the position of the lower c/arm brackets was pretty easy.

Once I knew how far back the engine would be in the frame by test installing
with the cab on, I made some temporary brackets and mounted the
trans. x-member in place at the same height as in the XJ. Then I set the
engine at the same motor mount height as the XJ. Then I measured forward
from the trans. x-member the same distance as the XJ had, and mounted some
more temporary brackets for the lower c/arms to bolt to.

This way I know the front diff. is the same distance away from the transfer case
as it was in the XJ and I'll have the same oil pan clearance. Then when I put the
upper c/arms at the same height as the XJ, I'll have the same drive line angles.

Then I figured out the angle that needed to be put in the front rail and notched
and welded the rail and mocked it into place. There will be plating at the connection between old and new frame.

The drawing below shows all the measurements taken off of the XJ before teardown
and a basic drawing of how the Toyota will look.
http://i6.photobucket.com/albums/y224/87xjco/Xota/xjmeasurements.jpg


The rails have some interesting bends to fab.
http://i6.photobucket.com/albums/y224/87xjco/Xota/ltrailview.jpg

I will bevel the edges and then weld up this second notch.
http://i6.photobucket.com/albums/y224/87xjco/Xota/railnotches.jpg

[87xjco]

I have the rails built and positioned where I want them.
10/22/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/rtrailview.jpg

Welded them to the Toyota frame. My vertical welds from the new rails to the old are not coming out to good.
Looks like I'll have to grind it off and put the frame on it's side for many
of the welds.
http://i6.photobucket.com/albums/y224/87xjco/Xota/railtackd.jpg

Made some plates to reinforce the connection and welded one of them on
http://i6.photobucket.com/albums/y224/87xjco/Xota/rtgusset.jpg


I have my spring seats and track bar mount bracket in place now. I got the spring seats off of a bent 05 Explorer frame that we had replaced.
10/25/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00021.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00019.jpg

Now with the springs in and no weight on the front it would be a good
time to bolt on the front shocks and extend them all the way out and position
the upper shock mount.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00022.jpg


I didn't realize until just now how tall the shock bracket will need to be.
I'll set the shock bracket so that the down travel will allow the spring to come out of it's seat by about 1 1/2". I will install some sort of limiter so that the shocks are not used as travel limiters.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00023.jpg

Shock mounts are in place. Just need to add some gusseting.
10/27/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00025.jpg

[87xjco]

Finally, the front frame mock up is done. Just need to get the frame off the diff's and add some more gussets and do some more welding and some trimming. Then I'll clean and spray paint frame.
http://i6.photobucket.com/albums/y224/87xjco/Xota/ltside2.jpg

As you can see I just have the rear diff. bolted up to some temporary brackets. I will wait to do the rear diff. fabrication until I have all the weight back on the frame. But I think I will swap the springs side to side and put the long side in the front to get a longer wheel base.
http://i6.photobucket.com/albums/y224/87xjco/Xota/Reardiff.jpg


Underside of the frame is done and painted.
10/31/05
http://i6.photobucket.com/albums/y224/87xjco/FRAMEUNDER.jpg

I am now able to bolt up the front differential. Since all 4 control arms are adjustable, I want to make sure it is centered and that the wheel base is even side to side.

Here is what I did;
1: First I leveled the frame
2: Then I found two holes near the rear of the frame that were in the same location on both rails. I tied a string that went from hole to hole and then I measured and marked center.
3: Then I did the same up near the center of the frame
4: Then I ran a string that intersected both those center points and tied it off on the temporary angle iron that is across the very front of the frame.
http://i6.photobucket.com/albums/y224/87xjco/FTALIGN.jpg
5: Then I tied a string across from each of the upper ball joint grease
zerks, then measured and marked the center.


6: Then I used a plumb bob hanging down from the center string and aligned the axle center with the plumb bob and then measured back from each ball joint zerk to a point on the frame that is equal on each side of the frame (I used the cab rear mount hole). Keeping the axle centered I used each adjustable upper control arm to set the distance equal on each side.
http://i6.photobucket.com/albums/y224/87xjco/RTALIGN.jpg

This should give me a front differential that has the same wheel base side to side and be centered with the frame. I'll use the lower control arm adjustments to set the pinion angle.

[87xjco]

Woo Hoo!

Engine is installed (hopefully for the last time) and frame work is all painted. Just need to do a little work on the spring seats (weld in some center tubes) and I'll put all the front suspension back together. Then I need to build a better transmission crossmember. And then... and then... and then...........
11/1/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/LTPAINTED.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/RTPAINTED.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/RTRAILPAINT.jpg

Suspension is all together except for mounting the steering gear.
When I was putting this frame together I basically just put everything in the same position as it was in the XJ and the XJ handled good. But after seeing the angle on those UCA's it was obvious that they need to be longer and repositioned like you see in the drawing. I'll do that later and post.
11/3/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/xota2edit.jpg


http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00046.jpg

[87xjco]

Cab is ready to set back on frame. I need to have cab in place to set up steering gear box and column and to run fuel & brake lines.
But it will come back off again later for painting etc...
11/4/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00048.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00049.jpg

Cab is set on frame. It will look alot better with some bigger tires.
11/5/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00050.jpg


I still have some work to do for clearance near the throttle pedal. I'd like to get about a 1/2" so I can put some heat shielding in.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00053.jpg

I couldn't really put the engine any further forward.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00055.jpg

Yes it runs!!!! Just started it for a few seconds as there is no radiator in place yet. I hooked up the wiring to computer,
relays, engine, grounds, etc.. I just routed the looms over the fender thru the window into the cab and plugged in the column.
I set the fuel tank on the back & hooked up the wiring and hoses and ran a ground. I wanted to make sure it would run again and
that I didn't have any new problems I would need to figure out.

It started easily and fuel pump runs. Now i'll start running the looms where they need to go.
11/09/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00059.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00058.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00060.jpg

[KToy]

alot of time and effort on this one. i think its cool but i think your gonna bust your d30 and d35 axles.

the only thing i think is you should of done a 4runner.

there is a guy that has one for sale for 50 bux on here its a frame nad 4runner body.

anyways nice pics man

[87xjco]

alot of time and effort on this one. i think its cool but i think your gonna bust your d30 and d35 axles.

the only thing i think is you should of done a 4runner.

there is a guy that has one for sale for 50 bux on here its a frame nad 4runner body.

anyways nice pics man

You're right I do exspect to blow out the D30 & 35 & once I do I'll upgrade

A 4runner just doesn't give me the hauling capabilities for engines, lumber etc. that I need from a truck.

[KToy]

i c

maybe an xtra cab would of been the ticket. ohh well you got it done almost gonna be cool.

[virgil]

kick ass............ that engine is full of torque. i've got a friend who ran the d35 with the superior kit and had a 304 and 38s .never broke. its cool to be original.

[vigilantejustic]

damn man, my freakin hat's off too you

it wouldn't be my first choice but you've got devotion

(and a pretty good shop from the loosk of it!)

I look forward to seein the finished product, you're gonna have a great story to tell anyone who asks you "Hey man... your toy sounds kinda different... and looks kinda different too?"

[87xjco]

I am Making some modifications to the brake pedal/steering column mount so I can use the XJ booster and column. I was lucky that the brake pedal is in the right position to bolt up to the booster rod once the booster is bolted thru these new hole positions.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00063.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00064.jpg

[87xjco]

I was able to use the old clutch master cylinder position and cut out a square that the engine harness can bolt thru to the interior fuse box & harness. The Jeep brake booster is bolted up now also.
11/15/05
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00065.jpg

Fuse box on the interior side of the firewall.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00066.jpg

[87xjco]

Turned the XJ gas tank around opposite of how it mounted in the XJ and built a frame out of angle iron that bolts to the gas tank and to brackets that are welded to the frame.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00067.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00068.jpg

[87xjco]

The metal work on the cab is done (I think that was harder than building the frame) So I lifted the cab back off and cleaned up all the welds and then primed the bare metal.
Then I applied seam sealer on all the seams, then I applied a layer of alum. backed adhesive sound deadener. Now it is ready to get the firewall painted.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00084.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00085.jpg

Had the painter spray it for me this morning
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00086.jpg

[RockinRunner]

well im jealous, even if it is on jeep frame, suspension, etc. :phatyo: i have thought about putting a jeep body on a toy frame and drivtain but just dont have the money right now.

[FLArunner86]

i think its sick!

but umm, if u doing all this work, are u gna put a cage of some sort lol so it doesnt go to waste?

[RockCrushinToy]

hell yea dude i have to give you props on your build up, that is A LOT of work!

im not a jeep fan at all but that is still way sick
lets see some updated pics when your done

[Mattchue X]

A few months ago when I bought My 85 X-cab I had thought about doing the same swap I have a `99 XJ with the 4.0. I love that engine. But out of ease I was going to swap a 4.3 tbi. I was a chicken and did not pursue this farther. I give you praise. This gives me hope... You have a beautiful build.

[87xjco]

Sorry guy's. I haven't updated this board in awhile.

Brackets are all built for rear diff.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00116.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00111.jpg

Now that the SYE kit is installed, I can have the driveshaft lengthened.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00157.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00224.jpg

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00239.jpg




http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00267.jpg


http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00264.jpg




http://i6.photobucket.com/albums/y224/87xjco/Xota/lfendersanded.jpg

[87xjco]

One more glaze coat on the rt. fender and it will be ready for primer
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00290.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00292.jpg


http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00300.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00301.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00303.jpg

Body work on the left rocker is happening
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00307.jpg

Rocker is primed
3/13/06
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00322.jpg
Rt. cab corner is repaired and primed and also welded the holes where the Toyota nameplates were mounted
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00323.jpg

[WrenchTwister]

you are sick.

creative, devoted, you can weld good, looks nice, hope it turns out great for you, but you are sick.

:grin:

[hilbiliecrawler]

hurry up and get some action shots of that thing its awesome im really interested to see how it works :grin:

[BigDaddy]

WOW....that is crazy how much work you put into your Joyota. Its looks like the very first pic is Chinamans? Were do you go wheeling at? Would love to see it in action. Post in the Trail Run section when your going out next time.

[shawn0890ss]

even though i would rahte see it wearing the toyota front end and badges still a very sweet truck man.

[RockinRunner]

its comin together very nicely. sweet ride man.

[87xjco]

3/17/06
It's ready for paint!!!!

Just need to mask it and get it into the booth.
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00335.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00338.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00337.jpg

Special thanks to Jamie Divos for the excellent painting.

http://i6.photobucket.com/albums/y224/87xjco/Xota/DSC00353.jpg
3/24/06 Bed is on
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00359.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00355.jpg

[87xjco]

Shameless posing
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00362.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00363.jpg
http://i6.photobucket.com/albums/y224/87xjco/Xota/Painted%20view/DSC00361.jpg