2004 Toyota Tundra The Master Plan

"It's kind of like an onion," Jon Lee says of his 2004 Toyota Tundra. "It doesn't jump out at you, but as you look closer, more and more details come out." Indeed. Jon's Tundra is plain white and sans graphics. Its track width isn't overly wide, and the ride height isn't that much taller than stock. Just the same, the onion analogy is dead on.

It all started with a master plan. Jon, of Riverside, California, is a long-time Toyota fan and a former Factory Toyota Master Tech. He wanted his prerunner to be capable, comfortable, and to fit his life as a backcountry explorer and as a co-driver of Pro Armor's Class One team. Those were the "big picture" parameters.

There's a Sol Tek quintet riding on top of the front bumper. Mark Johnson built an air scoop into the design. The scoop channels the air as well as the observer's eye.

There's a Sol Tek quintet riding on top of the front bumper. Mark Johnson built an air sco

To meld the big picture parameters with the small metallic details, Jon turned to long-time friend and fabricator Mark Johnson. "We decided to keep the stock dash," informed Mark. "That dash was taken in and out of the truck about a hundred times while we were building the truck, but we finally got a dash that fits around the 'cage tubing. All the accessories work."

After the first glance, the next layer you're likely to notice is the Ford-style I-beam front end. What's a Ford design doing on a truck owned by a die-hard Toyota guy? The master plan called for 20 inches of front wheel travel combined with a reasonable track width. Mark explained the dilemma: "To get 20 inches of front wheel travel with A-arms, we were either going to have to have a 105-inch track width or move the engine back several inches. Jon didn't like either of those options, so we went with I-beams." As built, the front end yields the desired 20 inches of travel and has a very reasonable 85-inch track width.

Check out the tire and wheel package. While 35-inch BFG Baja T/A's aren't exactly rare, the 5-on-205 buggy-style wheel bolt pattern is. Why use a buggy bolt pattern on a truck? The master plan, of course, called for it. This wheel-and-tire combo matches the one used on the Pro Armor Class One buggy. That way there's no need to carry separate spare tires for the buggy and for the Tundra.

One-piece hoods that take three people to remove them aren't all that practical for everyday use when you're flying solo. This front end tilts forward on Heim joint hinges. A stock 4.7 Toyota I-Force V-8 propels this truck, surrounded by 'cage tubing and Fox coilover and bypass shocks.

One-piece hoods that take three people to remove them aren't all that practical for everyd

The truck is not just limited to prerunning and chasing, though. "The first thing I did when the truck was done was to take my wife on a 600-mile trip through the Nevada desert. We saw old mining equipment, ghost towns-all that stuff."

Unlike an onion, peeling back the layers of this truck won't have your eyes watering in pain. It'll have your mouth watering in amazement. This truck goes to show what can happen when you combine a talented fabricator with a master plan.

Specs
VEHICLE:	2004 Toyota Tundra
OWNER/HOMETOWN:	Jon Lee/Riverside, California
ENGINE:	4.7L Toyota I-Force V-8
INDUCTION:	Stock EFI
TRANSMISSION:	Stock automatic
FRONT SUSPENSION:	Custom I-beam conversion by Mark Johnson, kingpin I-beams, parallel links
FRONT SUSPENSION:	in place of radius arms, Fox coilover and bypass shocks, 20 inches of travel.
REAR SUSPENSION:	Custom three-link by Mark Johnson, Dirt Tech trailing arms, reversed
	upper wishbone, Ford 9-inch axle with Cone Industries floater hubs,
	40-spline axles, 4.88 gears, spool for 100-percent locked-up traction, Fox
	coilover and bypass shocks, 23 inches of travel
TIRES:	35-inch BFG "Project" Baja T/A's
WHEELS:	BTR beadlocks with 5-on-205mm pattern to match the Pro Armor Class One buggy
OTHER DETAILS:	All California smog equipment present and functional, external battery
OTHER DETAILS:	jumper, Filtered A/C, GPS navigation with laptop Google Earth capability

Functional windshield wipers are tough to pull off if you run your cage tubing in the structurally ideal locations. The wiper motor is upside down on the driver's side now, but it started life on the passenger's side. Custom actuating rods move the all-important wipers. Jon lists the wipers as one of his favorite parts of the truck.
Functional windshield wipers are tough to pull off if you run your cage tubing in the stru
This is a Ford-style front end, so where are the radius arms? Parallel links keep the caster angle constant throughout the suspension stroke, improving handling. The lower link is adjustable so that the caster angle can be dialed to perfection.
This is a Ford-style front end, so where are the radius arms? Parallel links keep the cast
Another benefit to using kingpin-style I-beams is that the steering linkage runs behind the beams if you're true to the original Ford design. Ford never dreamed of a steering setup like this one. In place of a steering box, Mark used a Howe rack whose force is supplemented by a ram assist and protected by a Fox steering damper. In addition to protecting the linkage, running the tie rods behind the I-beams puts the rods in compression (better for tie rod end life) and enables a perfect Ackermann angle (better for cornering). The wide-set Toyota frame made it possible to run the steering rack and the swingset inside the frame rails.
Another benefit to using kingpin-style I-beams is that the steering linkage runs behind th

Kingpin-style I-beams are sought after for their brute strength, and that's what Mark Johnson built this front end with. Notice the doubler plates on the frame, which add vital strength to tubing attachment points. Mark notes that the steel used for the Tundra frame "...is on the thin side."
Kingpin-style I-beams are sought after for their brute strength, and that's what Mark John
The fiberglass fenders, front bumper, and BFGs hint at what's underneath.
Hidden behind a Dzus-tabbed panel there's a cabin air filter....

.....which makes all the difference when you're in the dust.
The rear suspension's upper wishbone runs opposite from the norm, but this configuration was the best fit. At the frame end, you'll find a burly rod end connected to a heavily-reinforced crossmember.
The rear suspension's upper wishbone runs opposite from the norm, but this configuration w

Here's a closer look at the full-floater hubs custom machined by Cone Industries to match a Class One buggy bolt pattern. The Fox coilover and bypass shocks also match the Pro Armor car's, and can be used as spares if needed. Mark Johnson called on Dirt Tech for the rear trailing arms, which are a custom version built just for this truck.
Here's a closer look at the full-floater hubs custom machined by Cone Industries to match
The onion analogy applies doubly to the truck's tail section. Everything's tucked away from prying eyes, but it's all there, right down to the spare drive shaft and the Hi-lift jack. Jon wanted to be able to stand on the bedsides if needed, so there's extra reinforcement under the fiberglass.
The onion analogy applies doubly to the truck's tail section. Everything's tucked away fro
This is a very civilized interior, even with the full complement of roll cage tubing. Mastercraft seats and Simpson belts keep everyone comfy and secure.....
This is a very civilized interior, even with the full complement of roll cage tubing. Mas

.....Everything still works, even the airbags. Jon can turn off the airbags so they don't deploy needlessly in rough off-road terrain.
.....Everything still works, even the airbags. Jon can turn off the airbags so they don't
BTR wheels come cast as a beadlock, which adds strength and safety to the beadlock assembly. They're also significantly lighter than many beadlock wheels on the market.
BTR wheels come cast as a beadlock, which adds strength and safety to the beadlock assembl
All of the smog equipment is present and functional. Jon's experience as a Toyota Master Tech came heavily into play here.
All of the smog equipment is present and functional. Jon's experience as a Toyota Master T

Easy access, and a place for everything. These features help ensure sanity on long trips.
The Hi-lift jack is tucked away under a cover between the spares. You'll also find a nitrogen bottle for running tools and inflating tires, and a 200-amp, 12-volt jumper system ready to help if you've got a dead cell.
The Hi-lift jack is tucked away under a cover between the spares. You'll also find a nitro

The floor of Mark Johnson's shop is clean enough to eat off of, not that we can confirm this from actual experience. Mark back-halved the Toyota frame to buy more room for bump travel at a lower ride height. Enclosure panels on the 'cage are a touch of class, boost security, and keep projectiles confined to the fenderwells.
The floor of Mark Johnson's shop is clean enough to eat off of, not that we can confirm th
Four-wheel drive isn't mandatory to successfully navigate the Afton Canyon crossing of the Mojave river, but it helps that Jon's Tundra runs a spooled rear differential for 100-percent locked-up traction.
Four-wheel drive isn't mandatory to successfully navigate the Afton Canyon crossing of the
This recently-quieted mine within the Mojave National Preserve was like a time capsule when Jon and his wife rolled up to it during a recent desert trip. It's on our "must-do" list of places to visit.
This recently-quieted mine within the Mojave National Preserve was like a time capsule whe