Has anyone ever accomplished this feat? I have read a couple of tech articles where this was done, with some conflicting data.
One guy spliced 12" into the center of his frame, vertical cuts, just welded both sides and boxed the frame. The second dude made vertical cuts, like a V, spliced in the frame section. Welded both sides, boxed the frame, and also sleeved the frame.
My question is which method is the best?

Best method: buy a 55!! :D

I lengthened a frame a few years ago, but never used it so take this with a grain of salt...

I had two custom "C" shaped channels made from 3/16's steel. They fit tight and had to be hammered into place. I then made a another C channel that fit into the area when the frame had been streched and it fit into the first unit to make a box like the stock frame.

The reason that I did not use it is that I gave up on the project. I was trying to build a 45 out of a 40 frame that I had. I think that it would have worked just fine though.

Work out well, FJ45's were lengthened kind of like this.

55 frames are stonger though...are they are cheap.

-Stumbaugh

Yep, in fact Toyota used this method to make FJ45 LWB frames. They started out with an FJ45 SWB frame, cut the frame on a diagonal and lengthened it by 12". After welding in the insert, the frame was sleeved with a piece of C-channel fitting over the regular frame.

The image below shows one of my 45 LWB frames with the sleeve removed. The insert was welded from the inside and the penetration was not deep enough to fill in the original cuts. The lines you see are the incompletely welded joints:mad:

http://darkwing.uoregon.edu/~jrice/cruiser/FJ45/FrameExtension.JPG

For my trail truggy, I removed 10" of the original 12" frame extension. This will give me a nominal wheel base of 106". The shortened frame with the sleeve welded over the joint is shown below:
http://darkwing.uoregon.edu/~jrice/cruiser/FJ45/WeldedBack.JPG

The Jeep guys do this all the time....

I don't see any problems as long as you thoroughly box the frame when you do it.

IMHO 100-103" is perfect on the trail. This can be accomplished without a frame extentions as Jimmy and I both proved.

If I were going to lengthen the frame, I would do it in front of the tub and add space to the engine bay right in front of the windshield.

This was I would have better cooling with a 350 and would not have a problem getting a hard ot soft top on.

Thanks for the inputs, much appreciated!
What I'm trying to do is make a hybrid 40/45 Cruzah. I was pondering lengthening the frame to allow for a custom bed, back half of a cruzah tub, or a flat bed. Either lenghting it in the section as where Medusa's pictures showed or add a few inches to the rear of the frame.
The only draw back I can see from leghtening the frame is the departure angle.
The advantages would be I can run longer rear springs, have additional room to run a doubler without worries of a extremily short driveshaft.
What do you think????
Medusa- Did you sleeve the frame on the inside of the rails?
:skull:

This was Teamaloha's Hybrid befor he BASTARDIZED it;)

Nolen,
Anymore shots of that bastardized rig??????

:smokin: :smokin: :usa:

I need a few for something I am cooking up!

You think it is Bastardized in that picture?

GO to my Photopoint below to the ARCA album and check out the "cockpit" style FJ that is red with a Chrome Bezel.

It is, *gasp*, the same truck!

Jason, that maniac, sliced and diced up that cool FJ-45 like a thief!

One positive note, he has a Kick Ass ARCA rig now though.

Maybe he will note this thread and post some shots from before it's "surgery"

Gracias Amigo!

Medusa- Did you sleeve the frame on the inside of the rails?

The area of the inside of my frame where the sleeve is located is the location for my 4-link hangers. As shown in the pic below these hangers are huge and will be welded to the inside of the frame along 14" scab plates. This will end up being the strongest portion of the frame - for sure.

http://darkwing.uoregon.edu/~jrice/cruiser/FJ45/LinkHanger.jpg

Those custom hangars for your 4 link are sweet, you've got skills! Looks like you have a serious welder in the background to handle all of you're fabrication needs!
Thanks for the replies!:skull:

That welder looks like the Millermatic 250 I have!:usa: :beer:

Yep, Miller 250X with the Aluminum spool to boot. It is a great machine:D

My Miller Matic 250 is my most prized possion. Best investment that I ever made in my shop. I could not say enough good things about it, even if it broke down I'd still love it