Our 1992 Toyota SR-5 4x4 project vehicle has come a long way since its adoption. What started out as a basic, stock truck has ended up a quicker, better-sounding, better-running vehicle (July/Aug. 2002). Due to its newfound acceleration capabilities, improved fuel economy, and a muscular symphony of intake and exhaust, we're happy with the performance.
| Hanging the 550s below the truck not only looked odd, but they became a target for rocks off-roading. Golly Adams of Billet Works widened the opening and repositioned the lights in the air dam where they belong.
Next is the truck's appearance. For assistance here, we turned to the folks at Performance Products, where lead mechanic Alfredo Mendigana installed our add-ons right on site.
Aside from the aesthetics, we wanted to build on the functionality of the vehicle. Red-and-black Wet Okole Neoprene seat covers, and gray Husky Liner floormats will replace the tired factory pieces that came with the truck. In less than 20 minutes, our interior had a new attitude.
| With the 550s in the air dam, the truck had only one problem, the position of the license plate behind the light bar. Legally, it's gray, so perhaps the Billet Works folks can create another miracle.
Our SR5's shocks and torsion bars were also tired after 100,000 miles of service, so Performance replaced the original Tokico shocks with Bilsteins, and installed a new set of torsion bars from Power Barz.
The setup has lifted the truck about an inch, but what it's done for the control and ride is what really matters. Going through hard dips now is a simple one-dip process, instead of the slight bounce the old shocks and springs were giving.
| Not only are the new Hella headlights much brighter than their predecessors, but they're easier to fix when they burn out. The bulb pulls out from the back of the shell.
Our first order of business on the exterior was to replace the stock steel air dam with a similar-looking, custom fiberglass unit allowing for the addition of Hella 550 Driving Lamps. Then came the Bugflector II adorning the hood, not only hiding the one scratch on the truck, but also protecting from flying objects, living and not.
Explorer ProComp of San Diego, California, provided the front-bumper-mounted light bar and off-road lights, also installed by the Performance folks. This is where we encountered problem number two--our bent tailpipe having been problem one. When dealing with aftermarket products, patience is more than just a virtue, it's a requirement.
| A new set of Bilstein shocks and Powerbarz torsion bars replaced the original Tokicos and factory torsion bars, raising the truck about an inch and giving a new sense of control.
Nellson Vels' Billet Works in Reseda, California, had the solution. Cutting a larger opening in the fiberglass and drilling a mounting hole on the frame solved the situation.
With all the new lights on the front, the original Sylvania headlights were a letdown. Back to Performance, who recommended and installed a set of Hella headlights. All this new electricity caught the attention of a city policeman, who pulled us over because it was rolling with the headlights off and only the Hella drivers activated. While some do this in an attempt to look cool, we were doing it in the interest of not blinding the driver in front of us. Stuck in traffic, and since a truck naturally sits higher than most cars, the headlights were shining directly into the passenger area of a vehicle. Using the air-dam-placed 550s, we still had lights but they shined at the rear bumper of the car, relieving the driver. The officer understood our reasoning, but advised us that driving without headlights, for whatever reason, is illegal. That said, he made us an offer we couldn't refuse; put the covers over the aftermarket lights, and no ticket will be issued. Needless to say, most of their value is used when off-highway.
| Neoprene seat covers resist liquids, helping to ensure the OEM seats will be saved for years to come, while the plastic floormats keep mud, grease, and liquids from getting into the carpeting.
So, as the project progressed, our Toyota moved better, sounded better, looked better, felt safer, and was a lot more fun. But it was still missing something.
To give the truck the look we had in mind, stylish yet rugged, we turned to KMC Wheels of Riverside, California. "KMCs were on a few Baja 1000 race trucks, and none of them bent or broke," says Jaime Zamora of KMC.
| Classically designed, the KMC Intruder wheel brought the 10-year-old Toyota into the new century, while Toyo Open Country tires offered less slip and more grip off road. Oddly enough, less dirt and mud ended up on the truck's body with the Open Country tires.
With a mind-boggling selection, it was a tough choice, but in the end, we opted for the chrome 16x8.0-in. Intruder--bold, clean, and classy, with an aggressive aura. While the truck tires were in excellent shape, and had served well, they weren't large enough to wrap around the 16-in. wheels. For new design technology and durable construction, we turned to Toyo Tires, which recommended its brand-new all-terrain tire, the Toyo Open Country. We immediately noticed the truck was quieter at all speeds. Also, while the tires aren't exactly the easiest to get used to in the curves on asphalt, possibly because of their larger profile, off road they shine. Together, the Toyos, Bilsteins, and torsion bars have made our off-pavement adventures a safer and better experience.
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With all this work done, the total cost is considerably less than that of a new truck, and it's brought more life to an old and trusted friend. Looking back, our most noteworthy additions are the lights, shocks, and torsion bars. The headlights alone illuminate the road extremely well, but when the air-dam-placed 550 drivers help out, visibility is improved even more. Off pavement, the ProComps join the Hella headlights and 550s give the impression we're driving around with stadium lighting. The only other tip is that, should any more lights be added, Performance and Pollastrini recommended a heavy-duty alternator to help eliminate the risk of battery burnout, overworking the truck's system.
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We like what we've accomplished, and, at just over 120,000 miles, it's running better than ever and has a new attitude for considerably less than a new truck. Possibly the most interesting part of the story is the attention people are paying to such an old truck, even those who prefer new rides. The chrome wheels, powder-coated light bar, auxiliary lights, and knobby tires gain attention in quick time. This combo makes everyone take notice.
