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2002 Toyota Double Cab Tacoma

As good as today's pickups are, some feel they just don't come with all the right pieces, so when we decided to build our own compact pickup tool, we had a lot to consider. We started our quest by being honest about our expectations: We were looking to put together a truck that would see heavy ranch duty in the Northeast, with intermittent adventures to the Upper Peninsula of Michigan for much-needed rest and relaxation. We weren't looking to overmodify our blank canvas, a 2002 Toyota Double Cab Tacoma, but we planned to increase its style factor, while vastly improving its rugged capability--all the while making sure we took every precaution to limit the corrosive effects of mud, salt, and rust. In a nutshell, we wanted to increase curb appeal, overall performance, and protection from the unexpected.

Our first stop was to "Project Double Take" headquarters at Performance Products, where we increased a rugged roof rack, headlight protection, and chrome stainless sidesteps--all in the name of installing function and protection. Inside, we followed the same theme by adding waterproof seat covers and heavy-duty deep-groove floormats.

In the bed, we placed a quick-disconnect Bed Xtender and hinged Sport Masters tonneau cover. For safety issues, we added extra lighting on the roof rack, with two forward-facing Hella pencil beams and one rear-facing work light. Also, when including the front bumper grille guard, we repositioned the front tow hook for easier access during potential off-road emergencies. We used some underbody coating to keep certain parts and pieces protected from flying debris, and we put a Warn accessory kit and tow straps behind the rear seats for emergencies. Underhood, we kept it simple for improved in-and-out breathing by installing a K&N Filtercharger kit and TRD cat-back exhaust--more air on the intake side and better noise out the tailpipe. Our final step was to improve our wheel and tire combination with a more aggressively treaded (Bridgestone Dueler A/T) tire and lighter (ASA) wheel to help with unsprung weight.

A word of warning: Don't just order parts and randomly start putting pieces on your vehicle. Considering each installation beforehand will save backtracking and possibly having to take off parts to install others. Planning prevents a lot of unnecessary work.

The entire project took two full days, once we decided on exactly the right parts for our needs and what installation order made the most sense. The overall result is a more capable vehicle with about 20 additional horsepower and increased attention-getting style. Now when we drive around town, we get more people doing the double take. | 2002 Toyota Tacoma Double Cab Pickup front Right While installing our front bull-bar, we noticed a problem with our factory tow hook. Because our Tacoma was equipped with a passenger-side in-facing hook, we swapped it to the driver's side to make it more accessible. | 163 0210 Take 03 Z A set of front-facing Hella 500 pencil beam lights will give us the extra candlepower needed for late-night backwoods exploration. When not in use, the lights must be covered. | 163 0210 Take 05 Z With versatility a main theme for Project Double Take, we decided a Bed Xtender made sense to create both a larger (tailgate down) and smaller (tailgate up) space when needed. Or we can easily remove it altogether. | 163 0210 Take 07 Z Inside the vehicle we needed protection from mud, snow, and dirt. Waterproof camo seat covers should repel liquids, while the heavy-duty floormats will help protect the carpeting from tracked-in debris. | 163 0210 Take 09 Z To free up some of the exhaust restrictions of the Toyota 24-valve 3.4L V-6, we went to TRD. The larger exhaust gained us about 10 hp and a much throatier baritone note. | 163 0210 Take 11 Z To finish our project vehicle, we moved to a more aggressive tread, but keeping the standard size, going with a set of Bridgestone Dueler A/Ts. In addition, we selected some BBS rims with a slightly more positive offset to bring the tires out from the fenderwells for a more muscular look. | 163 0210 Take 13 Z Installing the stainless chrome sidesteps and bull-bar is a simple bolt-on (brackets affixed onto the frame, using existing frame holes). Hand-tighten all nuts and bolts to properly locate the bars, and then tighten to specifications. | 163 0210 Take 02 Z For extra storage, we chose a Performance Products Safari Rack. The rigid frame and mounts will support up to 200 lb of evenly distributed weight. We used a drop of silicone at each hole drilled to help prevent future rust. | 163 0210 Take 04 Z Protection from flying rocks and road debris will be an issue where we plan to tread, so we opted for a set of pre-cut extra-thick plastic shielding to put over the headlights and blinkers. Several companies make plastic hood-protection. as well. | 163 0210 Take 06 Z In order to create some covered storage, we opted for a Sport Masters tonneau that offers a gas-strut-supported hinged option, just like a traditional trunk. With simple tools and a few quick-release connectors, the system is fully lockable. | 163 0210 Take 08 Z Further protection is provided by a Warn Accessory kit that includes a tow strap, heavy-duty gloves, 6 ft of chain, and various other vehicle-recovery gear. The thick canvas bag weighs about 25 lb. | 163 0210 Take 10 Z Swapping out the restrictive factory airbox and paper filter with a K&N Filtercharger took about three casual hours. The result is a cleanable, reuseable, cone-shaped air filter able to pull more air with less turbulence into the engine. The result gave us another 10 hp. | 163 0210 Take 12 Z SOURCES
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