1993 Toyota Pickup - Weekend Warrior: Part 1, Back Half

Since cutting stuff up is easily the best part of the rebuild, we jumped back to the rear and cut off the top of the notch so we could measure out the new rails for a simple back half using 2x3.

With the top of the notch out of the way, we measured how long the new rails would need to be.

After we measured and cut the rail for each side of the frame, we measured how high they would need to sit and we cut each one accordingly.

Once the rails are cut they're inserted and clamped together. With both sets clamped together they are tacked in place to assure they are equal and level.

The frame is measured and cut for the rails to be inserted.

It's crucial that the frame rails are level and parallel, so everything is triple-checked for accuracy before the temporary crossmembers are cut out.

The rails are tacked to the frame, and the temporary crossmembers are welded in to ensure that the new back half will remain level and parallel.

Holes are drilled into the frame so that the new rails can be structurally welded to the frame.

Unfortunately, it was the last straw for our drill, as it burnt up. We couldn't get the smell out of our nose until at least the fourth or fifth beer.

Once we finally got the holes drilled, a nice bead was laid down to permanently affix our new rails in place.

Here's a look at why it's important to weld the hole as well as the top of the new rail. The bead in the hole penetrates and creates twice as much strength for the new rails as just welding the edges.

With the crossmembers welded in and the new rails welded to the frame, now we could get back to the fun stuff and bust out the Sawzall to cut away the old frame.

After the stock frame was out of the way, we could weld up the rest of the new rails and grind them smooth. Here's a quick look at what patience and just a little know-how can accomplish in one weekend.

So to recap, we tore the sucker down, took everything apart, cut off all of the old crap, and got the new 2x3 rails set up for our back half. Not bad for our first weekend. Stay tuned as we continue the slow but steady process of a true mini-truck buildup weekend-style!