The Squadron Three Custom Off Road Trucks

A while back, we showed you how DMZ Fab & Race Prep builds a bumper. This time, we're bringing you not one, but a whole squadron of trucks built by DMZ.

First, Ryan McIntosh's 2005 Toyota Tacoma Doublecab 4x4 is equipped with a Total Chaos long-travel front suspension, complete with functional four-wheel drive. To this, DMZ added a custom bed cage, front and rear bumpers, long-travel spring-under rear suspension with Deaver springs, and completely boxed the frame.

Next, Jeff Valena's 2005 Tacoma Doublecab Prerunner sports a Total Chaos long-travel front suspension combined with custom-fabricated 2WD Allied steering knuckles. DMZ's Tim Duncan put the tie rods on steroids with custom clevises, chrome moly tubing, and Heim joints. Like Ryan's Tacoma, Jeff's also has a DMZ-boxed frame and Deaver-based spring-under rear suspension. Jeff wanted to be able to put his dirt bike in the bed, so Tim built Jeff's bed cage to accommodate moto-style cargo.

Both of these Tacoma's are highly streetable and serve as their respective owners' daily drivers. When it's time to hit the dirt, both trucks bare substantial off-road teeth.

Ernest Picos' 2000 Ford Ranger is a hardcore build that's ready for the starting line. For Ernest, it's a passport to fun: witness the "TKT BAJA" vanity plate. DMZ started with a Blitzkrieg Motorsports (BMS) long-travel front suspension system and took off from there. This Ranger has a bumper-to-bumper roll cage and a DMZ four-link rear suspension.

The DMZ squadron invaded the Ocotillo Wells OHV area on a crisp autumn day in late '08. Recent rains (yes, it does rain in the desert) made for a bit of mud, but also meant there wasn't any dust to speak of.

The squadron's trucks were put through their paces. Ernest's Ranger flew the furthest and landed the softest. No surprise there, since it's a full-race build. The unexpected came from the daily driver-style trucks. Whoops and jumps just aren't supposed to be conquered so easily by that which provides everyday transportation.

Joining the DMZ squadron is easy. Show up with a truck and a plan, and DMZ will take it from there. Have a nice flight.

Specs
Vehicle:
2005 Toyota Tacoma Double-Cab 4x4
Owner:
Ryan McIntosh
Chassis:
Stock frame fully boxed by DMZ, DMZ bumpers and bedcage
Engine:
1GR-FE 4.0 V-6 with AEM Intake and JBA headers
Drivetrain:
stock automatic transmission and transfer case, stock front and rear differentials with 4.56 gears and rear Lock-Rite locker
Suspension:
Total Chaos long-travel 4x4 front, DMZ spring-under rear, Fox coilover and bypass shocks.
Front travel:
13 inches. Rear travel: 17 inches
Steering:
Stock with Total Chaos tie rod extenders
Brakes:
Stock with Stoptech front brake rotors and pads
Tires/wheels:
35-inch BFG All-Terrain/American Racing
Interior:
OEM
Other Parts:
Lowrance 540c GPS, Tacoma audio package
Favorite Off-Road Area:
Mojave Desert, Pismo/Oceano Dunes, Big Bear, Baja

Ryan's Tacoma
DMZ's signature front bumper leads the way through the air.
Ryan's Tacoma came into his life after appearing on The Price is Right. Ryan didn't win the Taco' on the show, but he did win some prize money. The prize money and a trade-in at the dealer let him bring the Tacoma home. Glassworks Unlimited fenders and bedsides cover the 35-inch BFG All-Terrains.
Ryan's Tacoma came into his life after appearing on The Price is Right. Ryan didn't win th
A Total Chaos long-travel front suspension system gives the Tacoma real-world go-fast ability in the dirt. Fully functional four-wheel drive means Ryan can take the rough, steep stuff at a reasonable speed without fear of getting stuck. Ryan opted for T.C.'s optional Heim-joint upper control arms and weld-on knuckle gusset. Fox coilover and bypass shocks control the action.
A Total Chaos long-travel front suspension system gives the Tacoma real-world go-fast abil

Late-model Tacomas (and FJ Cruisers and 4Runners) have body mounts that protrude into spinning rubber as soon as bigger tires are mounted. DMZ trimmed and plated these to stay tucked out of the way. DMZ also pounded the fenderwell body seam flat in the name of tire clearance. Even with the 3.5-inch wider-per-side T.C. kit and Glassworks fenders, there's still a little tire-to-firewall contact with the 35s. Run 33s with this setup and you'll have zero rubbing, but you won't have the same ground clearance that 35s give.
Late-model Tacomas (and FJ Cruisers and 4Runners) have body mounts that protrude into spin
Ryan wanted the best of both worlds when it came to mounting his spares. Low-mounted spares are great in the dirt (low center of gravity) but get in the way when you want to haul cargo with a tail gate.....
Ryan wanted the best of both worlds when it came to mounting his spares. Low-mounted spare
.....DMZ built this system that allows the spares to be removed and the tailgate replaced as needed. The spare mount ties into the bedcage, which houses a pair of Fox 16-inch 3-tube bypass shocks. The rear bumper is also a DMZ creation.
.....DMZ built this system that allows the spares to be removed and the tailgate replaced

DeMello Off-Road rock sliders bolt on and protect vulnerable sheet metal.
It would have been easy to add some high-quality shocks to the stock leaf system, but travel would be limited and the rear suspension would lag behind the performance of the front. DMZ's spring-under conversion attacks the problem from every front. First, the stock spring-over leaf packs are swapped out in favor of a set of custom spring-under leaf packs......
It would have been easy to add some high-quality shocks to the stock leaf system, but trav

......Spring-under offers much more up-travel compared to spring-over. These springs, made by Deaver and only available with the DMZ conversion kit, are mounted in custom DMZ spring hangers and shackle brackets. DMZ mounted the Fox bypass shocks to the axle, and ran the shock bodies outside the frame to a custom bedcage. This setup produces 17 inches of travel, has next to zero axle-wrap, and rides smoothly.
......Spring-under offers much more up-travel compared to spring-over. These springs, made
Toyota's 4.0 1GR-FE V-6 is already healthy, but an AEM intake and a set of JBA headers up the power ante even further.
Toyota's 4.0 1GR-FE V-6 is already healthy, but an AEM intake and a set of JBA headers up
Getting lost is never an issue, and there's always some entertainment on tap.

American Racing wheels, BFG's 35-inch All-Terrain T/As, and Stoptech rotors and pads are the business-end "whoa" and "go" parts on Ryan's Tacoma.
American Racing wheels, BFG's 35-inch All-Terrain T/As, and Stoptech rotors and pads are t