Custom Transmission Crossmember

[Smithers]

In building my truck I placed the V8 Lexus 1UZ engine in a slightly different location from where Toyota put the V6 or 4cyl engines. In doing do the transmission was then moved as well. I made some steel plates to mount the transmission crossmember temporarily and in the last week me and my friend Josh were able to make the custom crossmember from some cold rolled steel plate finally. It's much stronger and obviously allows me to properly mount my transmission. Just thought I would share the process.

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_03.jpg

[Smithers]

Step 1: Remove crossmember and toss it aside. :)

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_04.jpg

[Smithers]

Step 2: Cut off mounting brackets from the inner frame with plasma cutter, grinders with cutting wheels and then grinding then flap discs.

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_07.jpg

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_16.jpg

[Smithers]

Now that the frame is prepped for new crossmember installation we gotta weld the crossmember together.

Steel plate fresh from the waterjet. Gotta love CAD!
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_20.jpg

Weld it all together and we're good to go.
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_17.jpg

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_18.jpg

[Smithers]

Now for a little of this and a little of that. Steel work is a lot of fun. I can't wait to put a roll cage in my truck!

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_05.jpg

Sizing the holes for the new poly bushings:
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_06.jpg

[Smithers]

My buddy Josh making the magic happen. I couldn't wrestle the TIG away from him if I tried. :D

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_09.jpg

Now time for some holes. Both the old and new cross members for comparison:
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_10.jpg

[Smithers]

And welding together the mounts that then will be welded to the frame.
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_12.jpg

Looking good. The adrenaline is pumping as the time is reaching midnight.
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_11.jpg

[Smithers]

4/2/2010 Now it's just past midnight and now we're getting somewhere. Welding the mounts onto the frame after a few minutes of measuring.

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_13.jpg

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_15.jpg

[Smithers]

So that all went pretty smooth. Now for kicks here is a comparison of the before and after. :D

With the hurtin steel plate type brackets I made to get the truck rolling... gotta do what you gotta do!
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_19.jpg

And the finished product! Very happy to have this done.
http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_22.jpg

[Smithers]

Ahhh much better.

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_21.jpg

And the BEST part: The transfer case and new crossmember don't hang down below the frame so much anymore.

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_23.jpg

[Smithers]

Now for some finish work and it will be rust free forever. I'll be getting the main part powdercoated and then just Hammerite paint the brackets off the frame. All in good time.

[jdmhn8]

Holy shit this is awesome. Looks great!

You really need to put together a mount kit for this swap to sell! The next HASPORT!

[Smithers]

$$$$$ Crap I don't think people would want to pay for how much this actually costs to produce. $$$$$ Here are a couple of action videos of the welding magic :D

MIG Action:
e5xPpzhT9E4

TIG Action:
cIEqcMVYwGU

[boy_uz]

A really hard / very well respected.

[Smithers]

It's a lot of fun and just takes time. I'm glad I don't do this for a living. :D

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_24.jpg

Had to cut out a section for front driveshaft clearance to connect the 4wd once again.

http://www.fourwheelperformance.com/1uz_tacoma/w59_1uzfe_crossmember_25.jpg

And here is he action shot of Josh putting in work with the welder:
t50kHfQhBfE

[boy_uz]

:p Welding Steel yourself for? / / Work out pretty much.