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Old 04-21-2008, 07:38 AM   #101 (permalink)
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Re: Project SAC'D FJC - Phase II

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How wide is the deck on your trailer that you have to run over the fenders? Mine's 82.5" wide but my 86.5" wide outside tire width fits without driving over the fenders (the sidewalls just push in).

Just wondering....

Sean
The deck is 82.5" on my trailer as well. I can get the tires to squeeze between the fenders, but it's just a bit easier to take one wheel over the fender.
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Old 04-24-2008, 07:44 PM   #102 (permalink)
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Internal Cage

Let the tube bending begin...

Over the next couple of weeks my FJC will be getting a lot of tube work. Don from FC Fabrication is doing the tube work and he does some really clean work. There are a lot of Landcruiser's (and other rigs) roaming around with Don's work on them.

The first project is the internal cage. It will be 1.75" DOM tubing. I originally thought that leaving the headliner in the FJC would be the best option. However, after trying to place a few tubes up high we realized that removing the headliner would give us tons more room and keep the tubes up away from my head. I decided to pull the headliner and apply some Extreme Dynamat and overlay that with some graphite colored headliner material that I bought at the local auto upholstery shop.

Headliner out. There was 3"+ of space above the headliner that we can now use. I also pulled the side curtain airbags. I will be pulling/disconnecting all the other airbags as well.




Prepping the interior. Don cut plastic to cover everything so nothing would get burned while welding. He also covered everything with welding blankets.




Today I installed the Dynamat on the ceiling. Used 10 squares.





Then I used some headliner contact adhesive to install the graphite colored headliner material. It came out OK. A little lumpy due to the shape of the roof, but I figure the top will be cut off eventually.





Don started working on the cage. He decided to build as much of the cage outside of the FJC as possible in order to limit the amount of welding he needed to do inside the FJC. The picture below is of the halo that will go up against the roof. The down tubes will be welded to the halo and go down through the floor.



Halo tacked together.



Fully welded halo. There is more tube, gussets and plating to be added.



Pretty welds.

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Old 04-24-2008, 08:03 PM   #103 (permalink)
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Re: Project SAC'D FJC - Phase II

You are right, those are some nice welds. I am really looking forward to seeing this beast in person, it is looking amazing...
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Old 04-24-2008, 08:07 PM   #104 (permalink)
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Re: Project SAC'D FJC - Phase II

Nice start. Any idea if the 3rd Gen 4Runners have that much room above the headliners?

I still haven't completely ditched the idea of building my 99, and an internal cage would be something I'd do.....just don't know if it's worth pulling the headliner. I'm definitely going through the dash though (if I build it).



Sean
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Old 04-24-2008, 08:24 PM   #105 (permalink)
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Re: Project SAC'D FJC - Phase II

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Mtbcoach previously said: View Post
You are right, those are some nice welds. I am really looking forward to seeing this beast in person, it is looking amazing...
Cool! I can't wait for Rubithon, it's going to be fun!

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Nice start. Any idea if the 3rd Gen 4Runners have that much room above the headliners?

I still haven't completely ditched the idea of building my 99, and an internal cage would be something I'd do.....just don't know if it's worth pulling the headliner. I'm definitely going through the dash though (if I build it).

Sean
Sorry Sean, I don't know if they have any room up there. The FJC headliner is a one piece molded unit that comes out easily. I removed the headliner in about 60 minutes. The dynamat/headliner material looks OK. Not perfect due to the multiple crossbars and elevation changes in the ceiling, but hey it's an offroad vehicle right... We talked about going through the dash, but I decided not to. When we did a couple of tests with pieces of tube I had plenty of room to move around and not whack and tubes. I just didn't want to go through the hassle of cutting into the dash.
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Old 04-24-2008, 08:29 PM   #106 (permalink)
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Re: Project SAC'D FJC - Phase II

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Cool! I can't wait for Rubithon, it's going to be fun!



Sorry Sean, I don't know if they have any room up there. The FJC headliner is a one piece molded unit that comes out easily. I removed the headliner in about 60 minutes. The dynamat/headliner material looks OK. Not perfect due to the multiple crossbars and elevation changes in the ceiling, but hey it's an offroad vehicle right... We talked about going through the dash, but I decided not to. When we did a couple of tests with pieces of tube I had plenty of room to move around and not whack and tubes. I just didn't want to go through the hassle of cutting into the dash.

I didn't figure you'd know but it was worth a shot.

I'm going through the dash just to save some room. I'm a little big for the Runner anyway, so I don't want to give up any more room for the cage.

Sean
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Old 04-25-2008, 12:18 AM   #107 (permalink)
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Re: Project SAC'D FJC - Phase II



That needs to go to the poser shot thread!
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Old 04-25-2008, 07:20 AM   #108 (permalink)
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Re: Project SAC'D FJC - Phase II

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[IMG]That needs to go to the poser shot thread!
I forgot all about that thread.
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Old 04-26-2008, 11:02 AM   #109 (permalink)
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Internal Cage Update

Update on the cage work for the weekend.

The top side of the cage was painted before going into the FJC.



Here the cage is being pressed into place with supports. Note the cool switch/cb tray that Don added to center of the A cross bar.





Positioned with ratchet straps.



B and C pillar support in place.



More next week...
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Old 04-26-2008, 12:25 PM   #110 (permalink)
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Re: Project SAC'D FJC - Phase II

damn I love seeing new pics of your ride
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