Total Chaos UCA’s and full 3” Sway Away suspension

Wanted a good lift and ride and found both in the these. The SAW’s carry the weight up front very well and never bottomed out when wheeling in Marble Falls at WTF 3. Excellent set-up. I had no sway bar up front so the front end is a little tipsy when cornering on the road but the payoff when off the road makes up for it.

5th - ? Modification
Basically at this point I went nuts…Anything that I could find with ARB on it went into my FJ. My wife kept seeing the UPS and FedEx guys pulling up to the house with boxes… The addiction was getting pretty severe:lol:
So I’m now the proud owner of the ARB Premium recovery package, Deflator tool w/ gauge, Bushranger X-Jack (AKA- the Orange Marshmellow- and it works very well and fast!)

Other additions:

10 lbs Powertank – “smoked bronze”- Spoke with the owners at Powertank since I wanted to know about how it worked and if it could run air tools like impact guns (very well!). Super great people and they answered all my questions and finished with a deal. They had tried to make a new color but were getting inconsistent results between each tank. So after only making a few they scrapped the color. It’s a smoked bronze and looks great! I got the tank with upgraded Nitrogen ready gauges, oil filled air gauge with air chuck, Bag with air hose and carry handle.
(funny- looks purple in these pictures)

1.25” Spidertrax wheel spacers- Wheelers Offroad
Pre spidertrax-

Note- this is more recent pic- the bump stop was added later on.
Baja Roof Basket (integrates with factory rack)- works very well and other than a little windnoise, has been almost in perceivable but very useful. I have thought about cutting the rear upper bar off so the whole roof could be used to carry larger items.

To be continued below!:wave:

 

More stuff!

Expedition One water cans- Used for WTF but actually never used them- just had them on the roof just in case.

Trail tool bag equipped with tons of tools from Harbor Freight, Craftsman, Home Depot and Wal-Mart

Installed a 2nd 12V plug in the center console and added hard line for CB.
Semi installed Cobra 45th anniversary CB with NC handset, 4ft Fire stick, Bandi mount and antenna tuner. CB had the “tune-up” done to it and its somewhat still legal… :lol:


48” Hi-Lift Extreme jack , Base plate, shackles- 4Wheelparts
Rocktek Slider lift attachment- TRD4U

Demello Hi-Lift attachment rings- Demello

Dirty Parts Dual Battery kit w/ Odyssey 1500 battery – Cruiser Larry-GB- Finally installed- Post 505

(2) Powerlift all in one truck lift – it’s a bottle jack with a jack stand together. Works great to keep in the back for lifted FJ’s. This has been the most used mod I have purchased.- Tractor Supply (note: doesnt work for the front end due to LT- now using the Hi-Lift)

Went to WTF 3 in Marble Falls, TX and saw some great FJ’s wheelin and having fun! Some of the FJ's in the pics are other members

MIGZ roof!

(5) 16”x 8” Bronze Konig Countersteer’s with 315/75R16” Yokohama Geolander M/T Plus. Probably the lightest wheels around for the $$. Look like Volk’s but a whole lot cheaper. Weigh only 18 lbs each but built for trucks! Tires were light too at 64 lbs. Main issue with the wheels- the distributer closed shop and he was the sole seller for these in the US. Makes them rare and different.- JDM Motorsports/ Discount tire

TRD Drop in Air Filter- Local dealership

A crap load of stickers…

So this was what it looked like!

To be continued...

 

G'day...
I like it..... don't stop, you're on a roll.....
Cheers
Baz

 

Wow Baz- your quick! I was posting while you jumped in!! :lol:

Thanks:bigthumb:

Holy Bejeezus thats one bad @ss ride!!!

Great build thread of an amazing rig!!

Thanks Bro!! Guys like you inspired me to write it all down!

So here it is...:rofl:

Even I dont want to reread it all...:lol:

:cheers:

 

More done...

Even blacked out the lights a bit with rattle cans…

The one on the right- left is used for the sliders.

So after driving the doors off the first year (Oct 2009-Oct 2010) and hitting 36,400 miles with no issues, I decided to let it sit for awhile since I wasn’t working in the US at this point and the mileage wasn’t even a consideration. From October 2010 to September 2011 I only put 1600 miles on it. For the most part of this year, my crack rock sat outside and became a magnet for bird poop…
Went through the “black out phase” while installing my rear bump stops from Timbren (sweet deal on eBay)

Before-

Ran my factory wheels w/ Pizza Cutters most of the time to not put miles on the road with my new tires and wheels. Also- couldn’t fit the 315 on the rear -needed new bumper first:lol: Didn’t want to get stranded.

Factory bumps next to Timbrens

Factory rear bumps

Timbrens

"Modified Timbren"- The only way you should run these

Started the “black out” with my wheels first! Satin Black over flat black over primer coat…

Ran out of paint- had to go to Home depot with half done rig to get more paint :lol:

Then I finished all the wheels and gave up on the “black out phase”… to be continued

So the warranty is up (been that way for awhile) so I’ve decided to have more fun, so I hit the pipe again…

This go round had me working with Sarah at All Pro working out a sweet new long travel set up with Fox shocks/ coilovers.

For the Front:
Ended up with their 2” LT kit for the front (longer UCA’s and LCA’s), welded spindle gussets, HD Steering system, 2.5” LT Fox coilovers with reservoirs, Timbren bump stops, extended SS brake lines, Currie 2” extended axles and CV boots . (sorry in advance- wife took these while I was overseas- not very excited and made no attempts to add presentation value…:lol

For the Rear:

2” Fox Piggybacks w/ 8 way adjustable settings, +3.5” AP rear springs, AP Lower links (these look like baseball bats!) and Upper Links, Extended SS brake lines and Timbren bumps.

Also picked up the Total Chaos Weld In Tower Gussets and Cam Gussets

More coming!!!

 

Started the install with my neighbors who helped with the mechanical side. The other neighbor set up the welder to run right for the application and then let me at it. I used to stick (Arc) weld so this was different with MIG. Buddies machine was a brand new Lincoln 140C which had infinite settings for wire speed and voltage- very nice!

Not bad I thought for my first welds- Booger welds!!

Used Wikid “wicked” CV removal trick- BEST way to remove a CV axle- took longer to tighten the “noose”- 3 slings with the hammer and out it came!

Ran into some issues with incorrect Cam Gussets –Note TC makes different ones for 2007-09 and 2010+. 2010 made the bolts much larger. So had to get new ones sent out and re-weld those- no biggie and props goes to Marco at Down South Motorsports for fixing the issue getting the parts out fast!! Great Customer service!

Ended up losing help (both had to work- I was off) and I was in over my head so I called in the big guns at GCCS- Enter Dave!

I figure it wasn’t a complete failure since it gave me a chance to see how to disassemble the entire front end- which now I know I can do!:bigthumb:

Dave workin the magic!!

TC tower gussets Fit/ welded in by Dave :bigthumb:

Cam gussets-

Factory

Total Chaos! Beefy!

And the LCA cam bolts fit the new weld in gussets!! Yea DSM and TC for making it right:bigthumb:

Keep going- its getting better!!:bigthumb:

 

The final product:

Additional gear:

Marlin Lefty- Note the missing stock transfer case crossmember- The Bud Built Tummy tuck crossmember is now bolted up. The large center bolt was for install and not under the crossmember now

Outridder Lower and upper link skids and 2nd gen shock skids.- TRD4U

Megan Exhaust- pre production for FJ- Too good of a deal to pass up.

PRP Competition seats

Bud Built Skids- 4" Tummy Tuck

Scorpion LED- 109 watt -5" Flood lights


Dirty Parts Dual Battery- w/ Odyssey battery

ARB 50 qt Freezer/ fridge with protective cover- TRD4U- GB (w/ slider on custom flat rack)


Ridged Dually D2’s- Amazon.com

Stealth Black A/T shifter/ 4WD knobs- Ellis Precision- GB

(5) 17” x 8.5” Trail Ready Bead locks with World Series Rock Rings (Blue Anodized) – Metal Tech- GB with 35" x 12.5" PitBull Rockers!!

Mrs OC approves of this mod!

Metal Tech ICON Omega Custom Rear Long Travel with LR Jounce Bumps in the coils



AP APEX DOM kick-out sliders


A crap load of even more stickers…




What the future holds…

Supercharger (when TRD finally releases it)
Fiberglass fenders
Currie Anti-Rock sway bar
Custom rear Axle with 4 link coil over suspension

A big special thanks to everyone on the forum who had directly and indirectly helped with this project (addiction) - My wife thinks I need an intervention!

Thats all Folks- more coming in the future as it progresses!

So if your a "meat and potatos" kinda person who wants the straight scoop with no filler and ya wanna skip all the chatter in between- jump to post #9. Otherwise enjoy the banter between the folks here on the forum. You could learn a whole bunch and get some great laughs in too- Thanks- OC

 

The final product:

Additional gear:

Outridder Lower and upper link skids and 2nd gen shock skids.- TRD4U

Megan Exhaust- pre production for FJ- Too good of a deal to pass up.

ARB 50 qt Freezer/ fridge with protective cover- TRD4U- GB (next to my 45 qt Yeti)

Old school 4WD land Cruiser badge- TRD4U

Ridged Dually D2’s (replacing the Pro Comps)- Amazon.com

Blue anodized custom aluminum Fairlead - Ellis Precision- GB

Stealth Black A/T shifter/ 4WD knobs- Ellis Precision- GB

(5) 17” x 8.5” Trail Ready Bead locks with World Series Rock Rings (Blue Anodized) – Metal Tech- GB
Mrs OC approves of this mod!

with 35" x 12.5" PitBull Rockers!!

Metal Tech Tube Doors- MIGZ

A crap load of even more stickers…

What the future holds…

Currie Anti-Rock sway bar
Re-gear to 4.56- add ARB locker up front
Marlin Crawler "Lefty" Transfer case w/ Competition CrMo 4.7- 23 Spline gears and 30 Spline CrMo output shafts
Bud built "Tummy tuck" skids- Hammertone Grey


Really Dreaming….:lol:

Hobart 180 Trail welder
Adventure Trailer with RTT
Supercharger (when TRD finally releases it)
Fiberglass fenders

A big special thanks to everyone on the forum who had directly and indirectly helped with this project (addiction) - My wife thinks I need an intervention!:lol:

Thats all Folks- more coming in the future as it progresses!

So if your a "meat and potatos" kinda person who wants the straight scoop with no filler and ya wanna skip all the chatter in between- jump to post #9. Otherwise enjoy the banter between the folks here on the forum. You could learn a whole bunch and get some great laughs in too- Thanks- OC

:cheers:

i wanna know about dually 2 with kits.I did bought oem auxiliary switch and wire harness for factory fj.But dually had 24 volts relay during oem fuse box following 12 volts relay come with auxiliary switch and wires harness under driver's side.I see that a-pillar 2 wire connector under hood for optioon to accessary fog lights or rigid dually d2.How about option for fog light switch to dually 2 without switch and 24 volts relay during oem wires harness and oem fuse and 12 volts relay? i need part number for 24 volts relay oem in fuse box or aftermarket 24 volts relay must fit in oem fuse box?

 

Holy Bejeezus thats one bad @ss ride!!!

Great build thread of an amazing rig!!

 

What Ive learned by all this madness!

If you want Long Travel- save your money and wait to get it all. I liked the SAW's and TC UCA's but my goal was always the LT set up. I think for IFS- the LT set up is as close as you can get to a SAS without an SAS...:lol:

Learn from what others have purchased and sold in member builds- it gives you insight into what didnt work or how making an impulse buy can be a big waste of $$ - trust me- I know this 1st hand!

So at the moment!


The ride is smooth. The HD steering is awesome- NO bump steer- works great and now eliminates the weak links.

Still trying to solve the setting on the rear adjustables but AP said to try "4" so Ill do that next

If you go this route- the AP LT UCA's have the zerks on the back (I called AP and suggested they place them up front). The main issue was the TC tower Gussets are in the way... So one popped off zerk its back at GCCS being made perfect! This stuff happens when you take parts from different manufacturers and place them together. blazing new paths where others can learn.

If your planning an LT set up, think big- as in cost- there are less expensive ways to do this but as I have found speaking to others on the forum and my installer- none of these are true "bolt on". So expect the unexpected!:bigthumb:

The AP LT kit offers spacers for standard lift (0-3") coilovers so if you cant do the whole shabang upfront- the spacers allow you to make it happen till you can get the LT coilovers. The TC and Camburg kits are super nice and well made. I went with All Pro's because I hadent seen anyone on the forum with one and the Taco owners rave about them. Another big factor was cost. While the standard TC (2") and Camburg (3.5") kits were closer to 3 large without axles, AP's was (w/ GB- $2400 w/ axles)- axles are about $500 and needed to maintain 4wd. So are they different? One better than the other. I'm not an expert and Ive seen all 3 kits. I would say that any of them would offer 95% of anyone on this forum a superior ride and keep up with about anything you can think of. The other 5%...well theres no helping you:lol: Your all to crazy and like to flip your rigs offroad:rofl:

Spacers or no spacers- With my new wheels in bound, I had to make a choice of back spacing. I went with 4.0" so with the spacers it would give me a nice wide stance and look mean! Ribbit!!

The Bull Frog!

Flexy is sexy

Yes...It does get dirty

Thanks for reading- Keep going!!!

Now jump to #14

 

Gotta say Toyeti is a beast......
so whats next ? !!!!!
ya can't stop now.....
Cheers
Baz
( sometimes down under is quicker..... hahaha) 3.07 pm here, Tuesday

 

Your killing me dude!!:lol:

When I used to work in Perth during the end of 2010 and start of 2011, no one even knew what an FJ Cruiser was. Then as I closing out my job there, I saw my first FJ in AU! I knew it would rock downunder

The time zones used to throw me when I had to contact people in Texas! Glad all is well in OZ!:wave:

:cheers:

 

G'day,
hahaha... are you back home then, thought you were still in Indonesia !!!
I deal with o/s clients and agents all day and all night long.... so I am used to it....
We are slowly getting more FJ's..... and selling them faster than supply. Still up to 6 months lead if you are fussy about the colour..... I lucked in on a VB, someone cancelled their order..
But ... the big question ... what's next....
maybe just a beer ... and a few weekends hitting the trails...... before winter sets in....
will give you time to adjust and plan the next mod !!! haha
Cheers
Baz
I'll have a coldie for you tonight, while I'm cooking the BBQ....

 

Beer sound great! Yup back home but heading back out soon. The birds are excited since they now have a clean truck to crap on. It was getting so bad, they had to aim to hit paint:lol::rofl:

Yea I know you guys have it rough over there with FJ's and back orders- we had the opposite effect. had tons on the market in the beginning and those who wanted one- got them cheap! 25-27 Large! Then in 2009 they made a third of the amount from the previous year and then they got popular... I waited 5 months for a white one.

I'd like to get a new 2011 TT in AG or the the new 2012 TT in RF but this has become my addiction.

Whats next- left a whole bread crumb list above-. Most likely get the Dually D2's, dual battery and exhaust installed. Get new tires for the BL's incoming from Delancy speedy delivery:lol:

Already got the approval for time off at Jambo 2012!! So Ill be there fo sho!

:cheers:

 

Almost forgot a mod...

CB antenna flags-

Got these custom made by ThreadworkZ Embroidery

Well made but dont try to go over 50 mph!

I never knew the fiberglass antennas could flex that much:worried:

Jump to post #39

 

He's got a few too many teeth...... hahaha
but I like em.
Cheers
Baz

 

great build, mod crazy!!!

 

Yes its been a crazy journey- even more nuts trying to find all the pictures and then get them in order.

Should have kept up with it when I was at each stage and wrote about it then. Seems nuts when I see it all.

Looking forward to seeing how it does at Jambo! Just got a call tonight from GCCS. The Toyeti is finished!

There is one dirt rode I promised myself I would "bomb" down (not sure if thats the right word). I wish I had one of those cameras that attach to the truck.

:cheers:

 

I think you should start planning for your second FJ, just to start again !!!!!
Yeah I know what you mean about scare ... I tried to haggle to dealer down.... he hardly budged, he didn't have to !!!! paid 49, for the VB.... and before you go ouch !!!! given the dollar parity .... thats a decent price ... here !!!!! but it sucks all the same.... any other car in Aust. and they are giving them away !!!! sales are slow..... but I am kinda glad supply is limited.... for now.... till the wife makes it impossible ... and I gotta get the RF for her....

See all part of the plan, to keep modding, thats why your beautiful lady needs one too....
hahaha....

Twin don't cost that much more than having one !!!!!!!

Cheers
Baz

 

Thats not going to happen- she likes fast sports cars. Besides I'm still pulling her fingernails out of the dashboard from WTF3:rofl:

She's not the wheeler type.:lol:

I thought with the way prices were down in AU, 49 wasnt bad at all. I thought it would hit 65 to be honest. You need the red one!!!



:cheers:

 

Old Cruiser,
I've read so many of your posts, listened to your comments, and looked at your pictures. At first I thought you were pretty cool. But now... Now...You... You just... You're a Rascal!!! :flame: Billy... pass me that pipe over there... :rofl::lol:
Your FJ looks awesome, Brother!! :cheers:
How do you like those Timbren Bumpstops?

I think AP should have another GB; Right about March...

 

Haha!! Well its all Chris Delancy's fault... he kept telling me things and I kept looking at his rig and Brian's... and then I woke up in bath tub full of ice with a kidney missing...But I got an LT on my rig:lol:

They havent run one in awhile- give them a call- they might work something out with you when your ready- super cool to deal with.:bigthumb:

:cheers:

 

Awesome rig!! Wanna trade?

 

Excellent!!! Lookin good brah!

 

Awesome build! Insane front end.

 

Great build thread! Can't wait to see what you do from here. :bigthumb:

 

Supercharger, 9" rear, front locker, 4.56 gears, and crawlbox.

Like slinging 'caine on the corner.

 

Nice build thread and really nice build. You have done some really nice mods, besides the obvious LT . I like how you've made upgrades to the structure, instead of just bolting on goodies. I look forward to following additions to your truck . ohh , Thanks for the mention too.:bigthumb:
Thanks for sharing
Don

 

Nice build thread and really nice build. You have done some really nice mods, besides the obvious LT . I like how you've made upgrades to the structure, instead of just bolting on goodies. I look forward to following additions to your truck . ohh , Thanks for the mention too.:bigthumb:
Thanks for sharing
Don

That's the best part... You guys really do things right. :cheers:

 

I love the stance of your truck; it looks amazing.

 

Looking at those Konig wheels kinda makes me walk funny. Bet they'd look sweet on a Sandstorm with dirt all over them. :browsmiley: How about hooking me up with a set ?

 

After the holidays, then.

 

PM sent. I'd like to stay married.

My wife is cool with it- I live on PB & J's overseas and save my per diem for mods. This way I'm trim and in shape, dont aquire strange stomach viruses and dont eat into "our" $$ :lol:

Awesome build! Well thought out, really nice!

Thanks Bro!! Ive watched yours take off!! Not sure on the well thought out part... Ive purchased stuff only to give away later or sell. I post this as a beacon of hope to save others $$:lol:

-OC

:cheers:

 

Awesome build! Well thought out, really nice!

 

So today i got a PM from Brazen asking about clearance from the spindle gussets to the wheels/ tires. So I went outside, pulled off the wheels and decided to show everyone what I found and at the same time show how to use a Hi-Jack since most (including me) dont know and practice is a must at home if you ever need to use it on the trail.

So here goes-

Spindle gussets

Basically the spindle is a weak link in the suspension for any lifted FJ with larger tires/ heavier wheels. Any easy fix is to gusset then using either All Pro's weld on gussets or Total Choas. Both are well made but need some grinding to make a better fit against the spindle. There is a great sticky on here on how to weld on the spindle gussets and how to remove the spindle so I wont bother with that. I will show you what they look like so youll know and not be asking yourself later...WTF is a spindle and why does it need gussets.

Here is a spindle (already had the paint removed/ prepped to weld on gusset. Basically this ties the upper control arm into the wheel hub and then to the lower control arm. See below.

The gusset is the thing with the holes in it to the left. Hub area was covered in tape to protect it from crap falling into the seal.

So you test fit and grind and then repeat. Its doest have to be perfect, just close enough to weld. Now most say not to try this at home...I dont listen well and to tell you the truth, this can be done at home ...IF you know welding and understand heat-affected zone. If this is not something you know- 2 options. Take the FJ to a shop to have them weld them on or order a set premade with core charge from Demello's and swap yours out. See below.

Then tack weld in areas to hold in place. I would suggest to place a bolt in the top where the UCA ties into to keep that hole lined up with the gusset. This will ensure it doesnt shift while welding and then not fir correctly whne done. See below.

Then weld it all up. I did it in sections to allow areas to cool. This prevents the metal domains for heating too quickly and for long periods of time that could cause deformities and weakness in the metal.

More on the wheel fit with spindle gussets next!!
-OC

:cheers: