This is my build. 90% bolt on. 10% file and grinder. Thus far, its been me flying solo on the install. Been a busy couple of days learning what NOT to do hahaha

The parts:
(Thank you Adrian at Icon for all the help)
TC UCAs
Icon Ext. C/O's
TC Diff drop
930 inner CV boots from Kartek
Home made brake proportioner riser
Icon/bilstein smooth bodies
14" straight through Muffler straight back to OEM up and over (bamufflers.com)
TC steering rack bushings (not installing yet)
Michelin LTX A/T2 285/75R16

The tools:
Hand tools
Wathelisrongwitu specialties slug press:
-A big ass socket (that still isnt big enough for the slug to fit inside)
-A big ass bolt and big ass washers
3 arm puller and a deep socker/washer to press upper BJ
Poofy cheetos
Bottle jack and wood blocks
Park tool bearing race press to press UCA bushings in evenly
C-clamp to press sleeves into UCA bushings
1/4" tap to clean powdercoat from zert threads (broke the first one off inside -UCA then broke the extractor off inside that haha all is well now)
Grease gun
Super mega grease capable of impregnating giraffes upon first sniff (obile synthetic)
Neo grease for CVs
Impact gun (super handy for loosening tough stuff)
WD-40 for aid with breaking things free

The Pictures so far:



http://i6.photobucket.com/albums/y207/wathelisrongwitu/Mufflerssss.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00168-20101125-1147.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00169-20101125-1148.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00170-20101125-1240.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00171-20101125-1359.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00172-20101125-1456.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00174-20101126-1437.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00175-20101126-1601.jpg

Cage mod. Icon instructions were wrong and it may be from demonic influence hahahaha.

http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00178-20101127-1531.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00177-20101127-1252.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00176-20101127-1252.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00180-20101127-1635.jpg

Cage?

Looks good so far. I see that BAM shining in the light. :tu:

CV cage mod. trim it back about 10mm cause even with a 1" diff drop the axle can still touch the CV cage. Basically there is a lip the stock CV boot sits on and you just cut that off and smooth it out. I havent HEARD my bamuffler in 3 days Im bummin haha. Cant wait to hear it when the headers come in (with the effing deavers Im waiting on)

And to be clear the Icon instructions that were wrong had nothing to do with the cage mod. They dont (as far as ive seen) advocate the CV cage trim.

All done. Sound clip and pictures tonight. Wheels arent on yet.

OK as it sits right now.......
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00186-20101130-0049.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/th_TruckRevBAMonly.jpg (http://s6.photobucket.com/albums/y207/wathelisrongwitu/?action=view&current=TruckRevBAMonly.mp4)
http://i6.photobucket.com/albums/y207/wathelisrongwitu/th_TruckMinidrivearound.jpg (http://s6.photobucket.com/albums/y207/wathelisrongwitu/?action=view&current=TruckMinidrivearound.mp4)

Alrighty. Pinch weld mod, fender trim, 1" hub centric adapters, wheels and tires, engine paint the stainless hardware. DONE! (untill the deavers, headers and clear corners get here). Also did the 05-06 tailight conversion. Also, painting the skids today cause thats how i roll. Ill get those up eventually.

http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00160-20101107-1459.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00161-20101107-1527.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00136-20101015-1754.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00191-20101204-2322.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00145-20101020-1757.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00192-20101206-1405.jpg


Can someone move this to a more applicable sub-forum? Its past suspension now. thanks.

Open water camo......or sky, haha

http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00193-20101206-1540.jpg

Looks great! I like your suspension choices:). Also your exhaust sounds really good, really good!! More vids of that please....

click thumbs for vids. Screwin around in the wee hours. You can hear my need to trim my fenders farther when my tires bump them as im jumping across the intersection haha

Warm idle walk-up
http://i6.photobucket.com/albums/y207/wathelisrongwitu/th_warmidlewalkup.jpg (http://s6.photobucket.com/albums/y207/wathelisrongwitu/?action=view&current=warmidlewalkup.mp4)

Windows up easy throttle then hard throttle
http://i6.photobucket.com/albums/y207/wathelisrongwitu/th_Windowsupeasyandhardthrottle.jpg (http://s6.photobucket.com/albums/y207/wathelisrongwitu/?action=view&current=Windowsupeasyandhardthrottle.mp4)

windows up then passenger window down next to a wall, then a "do not attempt this stunt" jumping the intersection moment. Hit it faster earlier on but didnt want to get too crazy holdin the phone haha.
http://i6.photobucket.com/albums/y207/wathelisrongwitu/th_windowupthendownwithwallandjump.jpg (http://s6.photobucket.com/albums/y207/wathelisrongwitu/?action=view&current=windowupthendownwithwallandjump.mp4)

Looks great! I like your suspension choices:). Also your exhaust sounds really good, really good!! More vids of that please....

thanks man. Your UCA install thread and pinch weld pictures really amped me up to get mine done. Not too shabby. Im still rockin my front sway bar tho :afro:

If anyone has questions or picture/vid/sound requests feel free to post up or PM me.

My motor setup is K&N drop in air filter to stock headers and Y with 14" bamuffler at Y to stock up and over tailpipe. Waitin on my JBA's :ballchain:

Cool thanks for the vids, sounds great! I like the tire rub!!! I might be doing something else with the pinch weld soon, so keep an eye out. Now get that truck dirty!!!

ya, I was leveling out my driver to passenger side tonight and I found where the rub was. The little 1/4" overhang of the fender flare at the top (1 o'clock) right where it can be trimmed out a tad. didnt think it would cycle that high to be honest hahaha *sigh* keepin an eye out for glass but most likely when I visit my jeep friend we will get it all to "fit" aka cut and hammered

Heres my front skid "clearance" with the diff drop. itll be cool untill it gets dented in. THEN comes the vibration rattle at certain rpms.
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00196-20101209-1806.jpg

Yes exactly. A buddy and I are planning on cutting and rewelding the entire pinch weld and making a new inner wheel well cover out of thin sheet metal. I want all the room I can get without glass. I too can rub my tire on the top of the wheel well when crawling over rocks and such. Without the sway bar the front really moves. Once I start thinking about glass, then I'll just want LT, and then, and then, and then....

Truth! Ya I think im going to pretty much tinker here and there till there is no more fender THEN if I screw it up, Ill get glass. Unless of course the right deal comes along. THEN my bank acct. is in trouble. LT 4x4, wheeeeew!

You picked up some Axis Regulators? Nice! I was the only one rocking black ones. Copy cat!:boink:
They look good. You are on a roll, keep going! :D

thanks man. ya I was bummed, lug centric so I had to get 1" spacers to get them on but they turned out to have almost PERFECT backspacing. $350 for the wheels then $317 to powder coat the wheels, rings and centers. THEN $75 for the stainless socket heads and washers, painted those babies with engine enamel semi gloss black and NOW $742 I have some trick storm trooper lookin wheels that Ive invested double what theyre worth. Thank God they look nice at least.

Suggestions on what to paint the other two skid plates?????? Im thinkin Zebra for the transfer case skid and an image on the tranny skid. We shall see.

Cage mod. Icon instructions were wrong and it may be from demonic influence hahahaha.


http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00177-20101127-1252.jpg
http://i6.photobucket.com/albums/y207/wathelisrongwitu/IMG00176-20101127-1252.jpg

Hey man, nice work so far!
When pulling the front axles, what oem pieces did you have to replace? non-reusable parts like seals, clips, pins, etc...

I replaced my pin holed boot and obviously matched the other side with 930's. Literally nothing NEEDED replaced. The parts you need if you do the cage mod are two boots, two clamps (you DO NOT clamp the little end of the boot onto the axle) and grease. Call Kartek and talk to Baja Mike and tell him you want boots for a ## tundra. 16 dollar boots, 2.50 clamps (threaded home depot style), 36 for a tube of NEO grease but i would get TWO tubes. i feel like I could have used more grease in my boots. SHYA BRA

However if you dont replace your stock boot 1) you're wasting your time and 2) you need new big and little clamps.

930's or bust!

I just got some new axles and a manual hub conversion kit and they need new boots, when i get around to actually installing all that crap Ill do a detailed write up on the cv's and boots since theyll be off the truck.

PS the axles I got (used) have 20k of manual hub miles on them (so hardly any) and the boots have a few holes in them. The boots are those big orange ones that are like 40 each. Im going to be changing them out to the same 930's I have right now. That should answer the next question ;)

Few notes:
Lots of grease
make sure to lift the lip of the boot off the CV to let the air out to equalize pressure

To get to the boots and the axle out:
Front end up
front wheels off
four bolts holding lower BJ onto spindle need to be taken out
take off inner CV boot clamps and slide boot back and get really greasy
pull on spindle and get cv to the edge of housing, take SNAP RING PLIERS and spread the retaining clip ALL THE WAY OPEN then lightly slide the axle in a LITTLE BIT then pull out all the way. Set spingle down and BE CAREFUL NOT TO PUT THE SPINDLE DOWN ON SOMETHING SHARP WHICH WILL CUT THE OUTER CV BOOT!
push cv to the back of the housing and pack cv housing with a rag and a cut out circle of a paper plate to keep shavings out as much as possible
trim the lip with a grinder with a little cutting disk SLOWLY AND CAREFULLY take your time and make sure youre straight
File off ALL BURS AND SHARP SHARDS
remove packing and clean cv housing
Slide new boot onto axle DUCT TAPE SPLINES AS TO NOT CUT BOOT
remove tape, open up the snap ring and press axle back into CV
Pump CV housing and boot full of new grease
slide new boot on and all the back onto the cv housing BREAK SEAL AND HEAR THE AIR PPPSSSSS OUT
clamp big end of boot down to CV housing
Put the four BJ bolts back into the spindle
Wheels on
Truck down
DIRTY TIME!!!!!!!!!!


I think thats it. Fun Fun.