Some things are too good to let go. After long-term testing an '03 Toyota 4Runner, I was hooked. The `Runner's 4.0 V-6 scooted along with ease and returned respectable fuel economy. Visibility was good, and the `Runner's dimensions fit well on most trails. The ride was smooth, and became even better when upgraded with a set of bolt-in Sway-A-Way shocks. Finally, the generous cargo space made it easy to stow plenty of gear for on-and-off-road adventures. The '03 was on loan from Toyota and had to eventually be returned. I dug through the online classified ads and found a clean used '04 V-6 4WD SR-5.
The goal with this `Runner was to create a comfortable, livable daily driver ready for the dirt with the flip of a turn signal. I wanted to be able to go anywhere, and four-wheel drive made the `Runner ready for the mountains as well as the desert. Because it's a daily driver, it was also important to build this vehicle with minimal down time.
As mentioned, the '03 tester I drove was fitted with a bolt-in Sway-A-Way shock upgrade which easily doubled the `Runner's capabilities in the rough, but retained the stock upper and lower control arms. I wanted to take the '04 a step further by adding a true long-travel front suspension system. Total Chaos Fabrication's long-travel front suspension was the perfect solution. T.C. offers its long-travel kit in two versions: two inches wider per side, and three-and-a-half inches wider per side. These long-travel suspension systems will fit '03-and-newer 4Runners, '07-and-newer FJ Cruisers, and '05-and-newer six-lug Tacoma's. The original thought was to use the two-inch kit, which does not always require flared fiberglass fenders, but T.C.'s Nicole Pitell advised that on 4Runners, tires larger than 275/75R16 would require fender modifications and possibly flared fiberglass fenders. Since the chosen tire size was 285/75R16 (33-inch), the 3.5-inch kit combined with a set of flared Fiberwerx fenders was the way to go.
As for the name Blackbird, it refers to a supersonic spy plane that was used before the modern B-2 took to the skies. Officially called the SR-71, the Blackbird was stealthy and fast: a perfect inspiration for this 4Runner.
After all the parts were in place, it was time for some dirt. The `Runner was pointed up a nearby canyon that's home to a mangled dirt road. Rocks alternate with fine dust and hard-packed dirt. In a stock SR-5, you'll gingerly creep along as the suspension bounces and bottoms. In an SR-71, you'll fly low and fast, slowing only for the big `gotchas.' Imagine doing 50mph where you could previously only do 25. Don't take this writer's word for it. Build one yourself.
 |  Here's the stock SR-5 behind...  Here's the stock SR-5 behind the '03 4 Wheel Drive and Sport Utility test rig. Nothing says `take me to the mall' quite like a set of stock running boards. |  Total Chaos Fabrication's...  Total Chaos Fabrication's 3.5-inch-wider-per-side long-travel kit provides a true 13 inches of 4x4 suspension travel. The added track width, a byproduct of the longer suspension travel, makes for stable cornering. The kit includes upper and lower control arms, urethane bushings, tie rod extensions, limit straps with an adjustable upper clevis, bump stop extensions, shock reservoir mounting tabs, extended brake lines, and all needed fasteners. In place of the stock ball joints, the upper and lower control arms connect to the steering knuckle via high-strength uniballs. The uniballs index into the tapered ball joint bores with custom adapters that eliminate the need to drill out the knuckles. Also shown are the custom 4340 extended axle shafts needed to retain 4WD. This system also works with 2wd vehicles which obviously don't need the 4340 extended axle shafts. |
 The lower ball joint is exchanged...  The lower ball joint is exchanged for a uniball that gives optimal strength and the misalignment needed for long travel.... |  ....This adapter housing starts...  ....This adapter housing starts with a CNC-machined billet plate to which a uniball cup is added with ultra-clean TIG welds..... |  .....The adapter bolts to...  .....The adapter bolts to the bottom of the steering knuckle in place of the stock ball joint. Mounting bolts are included. |
 The tubular upper control...  The tubular upper control arms exhibit the same quality construction and attention to detail as their lower counterparts. The uniball indexes into the steering knuckle with an adapter that matches the ball-joint bore, making installation easier because there's no need to drill the knuckle for a straight-shaft bolt. Note the gusset plate found at the uniball cup: added strength that inspires confidence. |  The lower ball joint is exchanged...  The lower ball joint is exchanged for a uniball that gives optimal strength and the misalignment needed for long travel. This adapter housing starts with a CNC-machined billet plate to which a uniball cup is added with ultra-clean TIG welds. The adapter bolts to the bottom of the steering knuckle in place of the stock ball joint. Mounting bolts are included. |  Toyota's forged steel steering...  Toyota's forged steel steering knuckle is strong, but it's still the weak link in the system. To get the complete system off-road ready, it's a wise choice to add the optional weld-on knuckle gussets. |
 Custom-machined 4340 chromoly...  Custom-machined 4340 chromoly extended axle shafts are needed to retain 4WD. In fact, if you drive your 4WD without the axle shafts in place you will do serious damage because the outer CV stub housings hold the hubs together. The T.C. axle shafts are inserted into the stock inner and outer CV joints. Since you must cut the stock CV band clamps to remove the boots, the T.C. axles come with hose clamps to secure the boots in place. |  Sway-A-Way makes these 2.5-inch...  Sway-A-Way makes these 2.5-inch diameter, 8-inch stroke coilovers specifically for the Total Chaos long-travel kit. The internal valving is tuned for the T.C. kit, as is the spring rate and preload. The shafts are made with Nitro-steel which resists rock chips for reliable operation and long seal life. A bump stop is mounted to the shaft to eliminate metal-to-metal contact at full compression. |  The upper shock mount bolts...  The upper shock mount bolts into the stock coilover mount without needing to notch the OEM coilover tower. This is possible with the S.A.W. shocks because they use an external top cap and hence have a shorter overall length compared to shocks using internal top caps. The shock reservoir hose has a slick fitting that allows it to swivel to any angle. This versatility will make it easier to install the reservoir mounts on the frame. |