I used to drive a CJ7. Like many of you, I've found that almost every modification that we make to improve the off-road performance of our trucks comes at the expense of operating these vehicles reliably on-road. I bought a Jeep with a mild 4" lift and 33" tires and six years later I'm climbing into a Kevlar tub and V8 drivetrain sitting on top of Dana 60 axles and 39" Super Swampers. So I purchased a 1996 4cyl/5spd 4wd standard cab, base model Tacoma with 90,000 miles for $8,000 and will be documenting the progressive build-up of a capable, all-purpose, 4wd prerunner type truck that will NOT compromise on-road performance and reliability. Instead of straight axle swaps and the like, we will be focusing on upgrades that will IMPROVE things like high speed/on-road handling/ride quality and the types of performance upgrades that a person would want to drive every day.

We'll install, evaluate and compare the full-on desert performance, long travel Tacoma kit from Total Chaos. It's 3.5" wider per side, 13" of travel vertical wheel travel (retaining 4wd, using stock Tundra CV shafts) to the stock width Total Chaos Uni-ball upper control arms and Swayaway coil-over shocks .

Fiberglass fenders and bedsides will be mounted in order to fit larger tires, accommodate suspension travel, and cover the width of a Total Chaos long travel kit. We're keeping this vehicle light and low, gaining wheel travel without dramatically changing the ride height from stock.

IFS upgrades and products ranging from wear-resistant CV boots to axle shafts and CV options, like modified Tundra components and custom Porsche 930 CV's are being researched and will be reported.

62" Deaver leaf springs are going to be installed on the rear of the truck with 2.5x16" travel Swayaway piggyback reservoir shocks. This setup will provide 18" of vertical wheel travel with minimal lift, and we will be investigating and explaining aspects of suspension design from shackle length to shock placement. Bed space, the utility and function of a truck will be preserved to the extent that it is possible.

Performance upgrades will turn to the engine compartment and drivetrain, with a focus on efficiency and fuel economy. We chose to build a 4 cylinder 3vz engine truck because this 150hp 2.7L dual overhead cam engine is a ripping successor to the infamous 2.7L 22re, and we're tired of getting 10-12mpg in our full sized trucks.

We will address the driver and passenger's protection and comfort in the usual ways, but with extra thought paid to the execution. Intrusive, jungle gym rollcages are out, but we will be installing comfortable bucket seats and harnesses mounted to minimal, lightweight tube-work as we turn our attention to building a chassis that will hold together after hard off-road use.

More miscellaneous fabrication and upgrades will follow, as we assemble a truck that we can drive to work through the week, load the bikes into, take four wheeling through all types of terrain, camp out of, and still depend upon to get us home and to work on Monday.

Stay tuned with us.