1992 Toyota SR-5 Truck Project

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.