Everyone with aftermarket bumpers or who jumps thier FJ should check this area. Closely.
Really.
I don't think the bumper issue has any relation to this problem - its not breaking from the bottom up, its tearing from the top down. It's the body flexing that's causing the cracks, not the weight of accessories mounted to the frame of the vehicle. I'll bet we'll see the same cracking on vehicles with factory bumpers, if not already, than soon...
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" I'm not aware of too many things, but I know what I know, if you know what I mean..."
"Your enthusiasm for the subject borders on the interesting..."
Therefore, my plan will be to let it happen and then just leave it. If there has to be flexion at that point, then thats what it will be allowed to do. I looked at all the parts anchored onto the body forward of that location on both sides, and absolutely none of it would suffer. There's the radiator (which is attached to everthing else by flexible hoses) the battery (attached with wires) and some various other tubes and wires that I can't see having a problem with additional flex. The air system is rubber. My ARB compressor is on top of the wheel well, but its connected with wires and hoses.
If there's annoying flex and rattle after that, I'll weld on some supports and destroy the flexion point... and I'll just see what happens.
It's only body metal.
I agree with your analysis, and have though similarly about how to resolve the situation. The only issue with leaving the flexed area separated, is in the case of a few other FJCs, continued off-road use seems to allow the fender, which is attached to the inner fender well and is now partially destabilized, to shift back towards the rear of the vehicle and impact on the door edge. This now damages external sheet metal, and inhibits door opening - one reason why Air2Air's repair estimate came to 15 Gs.... THAT is the situation I am hoping to prevent, and none of the solutions (including having the inner fender well replaced completely, only to have the problem recur) presented so far will prevent that scenerio...
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" I'm not aware of too many things, but I know what I know, if you know what I mean..."
"Your enthusiasm for the subject borders on the interesting..."
I know a lot more about fighter jets than I do about trucks and I'm also (uhhh) drunk right now, but what CruiserLarry and BellyDoc said makes a lot of sense to me. Which means this will probably happen to every FJC that gets flexed a lot eventually, it's just that you guys and Air2Air reached the metal fatigue / breaking point before everyone else. (Hope you guys will pardon me for the partial quotes.)
It's not the partial quotes that upset me - it's that you didn't offer to share the booze....
__________________
" I'm not aware of too many things, but I know what I know, if you know what I mean..."
"Your enthusiasm for the subject borders on the interesting..."
Area in question. Drivers side, right below the recess in the metal.
This is the view from the top. It appears the body, right under the recess is bulging out ever so slightly. This would make sense if it started to tear from the top.
I have no aftermarket bumper. I have stock size bfg ATs and Donahoes up front. It's only lifted 2" at the most. Just enough to level it out.
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"I'd like to die in my sleep like my grandfather. Not screaming in terror like the passengers in his car."
Ti, Roof Rack, Rock Rails, 16" Eagle Alloys with stainless faux beadlocks, Donahoe coilover 2.5" lift, All Pro LCA skids (Better late than never. Unfortunately... I was late.)
I just don't see how raising it up would cause the body to flex more. Even if it was the lift, mine was installed at the dealership.
Besides, the TRDs are lifted, albeit a space lift... what would be the difference in how it would effect any flexing. Assuming it's the body flex.
__________________
"I'd like to die in my sleep like my grandfather. Not screaming in terror like the passengers in his car."
Ti, Roof Rack, Rock Rails, 16" Eagle Alloys with stainless faux beadlocks, Donahoe coilover 2.5" lift, All Pro LCA skids (Better late than never. Unfortunately... I was late.)
Area in question. Drivers side, right below the recess in the metal.
This is the view from the top. It appears the body, right under the recess is bulging out ever so slightly. This would make sense if it started to tear from the top.
I have no aftermarket bumper. I have stock size bfg ATs and Donahoes up front. It's only lifted 2" at the most. Just enough to level it out.
I can't even figure out where that is lol. I looked at that then mine every which way , man do I feel dumb. Do you have a wider angle so I can place it?
Edit: after reading bernd's response below, I still don't get it. I can find his spots but that angle just killed my brain. Time for sleep.
toddunderscore keep an eye on that area. thats were mine ripped.I don't know if it ever bulged because I just noticed the rips today. Everyone who uses a FJ on the trails should take the time to look at these areas.
bellydoc
I've had all day to think about this. Believe me I never stopped thinking about it. I tested my rig in my driveway and watched it flex. I have come up with the same conclusions as you. Welding something on would shift the stress points. I am going to take it to Toyota and see what they tell me. Probably get the run around. Time will only tell. I'd like to thank you for the time you and the rest of you took to help me with this problem.
Homedadr
I do thank you as well for taking the time out of your day to test and twist your rig along with me.
We need to watch these areas closely and document the problem. In case it leads to more stress related areas. Thanks to all that have posted.
Not likely - the lifts affect the vehicle from the frame down. These inner wheel well cracks are isolated by and attached to the frame by the body mounts, which are unaffected by the suspension / spacer components. It's definitely a body flex / fatigue issue, not a suspension lift issue, IMO.
Can we start a poll to monitor the instances of these cracks?
I'd like to monitor whether the vehicle is:
A) lifted
B) has larger tires
C) if used off-road
D) has aftermarket bumper
E) mileage when first noticed
__________________
" I'm not aware of too many things, but I know what I know, if you know what I mean..."
"Your enthusiasm for the subject borders on the interesting..."
