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Discussion Starter #1
This is our FJ Cruiser build that has evolved over the last two years. When it came in, the 2008 Toyota was riding on a Stage 5 Icon suspension, 33" MTZ's, modified fab fours bumpers, sliders, Bud built skids and a TRD brake upgrade. "Stage 1" involved Total Chaos knuckle gussets, eccentric cam bolt gussetts, and a Inchworm Lefty t-case with 4:7 gearing and twin sticks.

As she came with the Icon suspension



Total Chaos knuckle gusset



Total Chaos eccentric cam gussetts



Fab Fours bumper modified with a grill guard and LED bar, Bud Built skid



Inchworm "Lefty" 4.7 t-case



twin sticks



aluminum console trim

 

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Discussion Starter #2
Stage 2 happened a month later after Ed saw our 05 Tacoma build. While we did rip off the front suspension, it got re-used on his daughter's 4runner. What replaced it was 2" over Total Chaos long travel kit with the upper a-arm gussets, lower a-arm skids, King 2.5" coilovers and bypasses, 1.25" roger Brown body lift, and 35" Toyo's.

Icon suspension before tear down



suspension laid out after coming back from powder coat



upper a-arm gussets



new Total Chaos installed



bottom view



front view



full frontal

 

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Discussion Starter #3
After he got it back, it wasn't fast enough. Stage 3 was a TRD supercharger, APR X1 piggy back fuel management system with 7th injector, cam gears, smaller pulley for 8 psi of boost, Doug thorley long tubes, O2 simulators, and a 2.5" stainless exhaust built out of pre-bent mandrel pieces. In the name of performance, it was also regeared with 4.88 Nitro gears and a front ARB to rival the factory rear e-locker.
 

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Discussion Starter #4
Stage 4 was literally a month after... Off went the Bud Built skids. Chris (85mudblazin) cut off the trans crossmember and built a new one flush with the bottom frame rails. Ed wanted 6061 3/8" skids with as much ground clearance as possible. We CAD'ed all the pieces on our Torchmate, and Chris TIG'd it up. Countersunk bolts are used to flush mount the skids.

the front skid is flush with the edge of the bumper



access panel for the oil pan drain plug



this shows the transmission skid and the gas tank skid



close up of the gas tank skid



flush frame side shot



gas tank bolt strap protectors



beveled lip and countersunk mounting bolts

 

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I saw this one on your website. Definately one of the nicest FJC builds I have seen on the web. Cheers to the work you guys did.

I am surprised I have never seen this one on the trails at various TLCA events. I know you guys work on Nick's FJC...which is the nicest FJC build I have had the pleasure of seeing in person.
 

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Nice work. Really like the finishing details on the interior to conceal the shocks/coilovers.

Great build,
Have you dyno'd to see what you HP are with the power upgrades ?

Curious to see how the lefty works out with that HP.

Is it running standard XD gears or trail gears? The majority of the lefty cases that have failed in FJs were those with S/Cs (running stock boost). He might want to consider upgrading to the chomoly competition series if Marlin ever gets the 23 splines in stock again, they've been out of stock since October of last year.


Hopefully see the owner on the trail some day. Haven't seen him at any of the TX parks/events before, but perhaps thats cause his FJ seems to have a long term residency at your shop :laughing:. Turned out well.
 

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Discussion Starter #11
Great build,
Have you dyno'd to see what you HP are with the power upgrades ?
We had it dyno tuned when we put the APR X1, cam gears, 7th injector, and the boost pulley. At the wheels through the 6 speed manual, t-case, 4.88's and 35" tires... it had 300 HP and 284 ft pounds. The tuner thought it was close to 400HP at the crank, and said the parasitic loss was huge with the big tires and low axle gearing.
 

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Discussion Starter #12
Nice work. Really like the finishing details on the interior to conceal the shocks/coilovers.




Curious to see how the lefty works out with that HP.

Is it running standard XD gears or trail gears? The majority of the lefty cases that have failed in FJs were those with S/Cs (running stock boost). He might want to consider upgrading to the chomoly competition series if Marlin ever gets the 23 splines in stock again, they've been out of stock since October of last year.


Hopefully see the owner on the trail some day. Haven't seen him at any of the TX parks/events before, but perhaps thats cause his FJ seems to have a long term residency at your shop :laughing:. Turned out well.

You hit the nail on the head. It hasn't had any real world testing besides the fire roads on his ranch, because we keep working on it. I can't remember the specs on the Lefty because he bought it. But knowing him, if there was an upgrade option he would have sprung for it. If that Lefty gives us problems, we'll throw a Stak or Atlas. i don't want to blast anybody, but we had some noisy bearing issues with that transfer case when we first installed it.
 

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i don't want to blast anybody, but we had some noisy bearing issues with that transfer case when we first installed it.
Fully understand. When my inchworm lefty with XD Gears sheared off a few teeth on the 4lo gear set, I wasn't exactly pleased with the customer service that I received - warranty wasn't what was advertised.

Ended up ordering from Marlin directly and went with the 4320 gears the second time around and was much happier with the service, even gave a better warranty on the failed case than the other mfg.


Toss of some pics of the rear interior whenever you guys get a chance. Turned out really clean.
 

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Discussion Starter #14
speaking of the dyno numbers, less than 2000 miles later after the performance mods, the 4.88 Nitro gears exploded. The Yota axle couldn't handle the torque of the motor and the stress of 35" rubber. We had just finished the Rockjock 60 in Nick's FJcruiser, and decided there were too many compromises with space constraints using that axle... factory frame, gas tank location, height of the link cradle, what had to be removed to properly get the most out of the Metaltech 3 link.

So we cut the frame off behind the rear doors, did a traditional upper triangulated 4 link, got Currie to weld on FJ outer flanges to a chromoly Fab 9 housing. Hi9 built the nodular 35 spline 3rd with an ARB. Fuelsafe built us a custom baffled cell that utilizes the factory Toyota pump/sending unit. Chromo heat treated links from Taylor at Herretic Fab and heims from Dan at Ruff Stuff were ordered. Sonny and Marco from Downsouth Motorsports built our 12"x2.5" King coilovers and triple bypasses.
 

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Discussion Starter #15
Here's tearing out the old e-locker Toyota axle and Icon rear suspension.



Currie and Hi9 test fit



care package from Downsouth



all the gusset work is TIG'd 4130 .120 plate







Backbone truss completed



Chris used stacked plate and weld washers for all the link and shock mounts



 

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Discussion Starter #16
Adjustable upper link mounts









here's mock up while we made the frame, shock mounts, and measured for the fuel cell



interior shot



lower shock mounts



housing with upper link mounts, bump pads, shock mounts, limit strap tabs



close up of the limit strap tab and bump pad



shock mounts, the hole is for the swaybar link

 

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Discussion Starter #17
Here's our fabricated frame out for final welding and fish plating, you can see the bump cans





final assembly with antirock swaybar and axle housing back from powdercoat



rear view



interior view



upper shock mounts





finally on its own weight again



22 gallon Fuelsafe custom cell in 1x1 steel cage, shod with 6061 3/8" skid



 

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Discussion Starter #18
view of the brake line routing



evap relocation





4 link frontal



upper link mount and view of flat belly skids/t-case cross member



This was after a much needed wash and long awaited test drive





 

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Discussion Starter #19
As for the interior, we made the wheel tub out of .066 thick aluminum. Chris TIG'd it. Then we sanded a crisp edge on all the panel work and trimmed the interior panels to fit around it

resi's mounted and experimenting with sound deadening





the aluminum tub











 

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Discussion Starter #20
interior side panels installed and retains the factory rear seats







 
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