started on the crossmember ..

started with cutting off the original mounts
[Linked Image]
[Linked Image]

also got some frame plates cut , and "placed " .

[Linked Image]

also got the "mounts" completed ..

[Linked Image]

[Linked Image]

then made a "trace" of the original mount holes , and cut the lower crossmember

[Linked Image]

[Linked Image]

BUT WAIT ... "says to self" ---- "self" .. better lay the header pipe in place to make sure everything will fit .


[Linked Image]


so I layed the "header" pipe where I thought it should be , had to watch out for the shackle clearance and such , and sure enough , it would have hit the crossmember .. so I think I have the crossmember figured now , but I figured I might as well get the crossover done , and in place first .

heres the pic of the cat , and the shackle clearance ... just for referance .
[Linked Image]

so I chopped up the old crossover ..
[Linked Image]

some guys have "re-worked" the old pipes , and expansion joint , I decided to go all new .

cleaned up all the old flanges , and put them in place ..

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0573.jpg[/img]

made a "template" of the first pipe , and ran of to get it bent . smile

trimmed it up , and cut it to fit ..

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0575.jpg[/img]

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0576.jpg[/img]


the stick indicates the firewall


pipe #2

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0578.jpg[/img]

and pipe # 3

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0580.jpg[/img]

a little triming (a LOT of grinding)
and a tack here and there , and finally I can weld .

I talked to the muffler shop , and the pipe bender guy suggested staying with the original Toyota flex joint , as they are WAYYY better then the aftermarket ones .. so I cut it out , and re used it .

starting to weld ....

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0581.jpg[/img]

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0582.jpg[/img]

and fully welded ..
[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0583.jpg[/img]

part of the reason for this excersize , was I really wanted to have the original heat shield back on .. and TA, DA ..

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0584.jpg[/img]

and some clearance pics ..
[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0585.jpg[/img]

and water pipe clearance .

[img]http://i76.photobucket.com/albums/j2/bj_bumperboy/MY%20Trekker/HPIM0586.jpg[/img]

total price ... [color:"red"] $30.00 [/color] + consumables , and my time .


now I can finish the crossmember .


smile

Last edited by CJM; 04/24/08 03:55 PM.

86 4x4 , fiberglass bed , 1/2 doors , hood, etc..
84 Custom 2WD 400HP supra suspension , full frame
83 Trekker SR5
NEW Trekker forum