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Ok, my last build thread documented all the trial and error I went through to optimize around the Rough Country 6" lift kit. Briareos's Build
That build taught me many lessons, and overall I really liked my 2009 FJ - there is little substitute for effortlessly running 35" tires and the enjoyment of driving something far different from the norm. If it wasn't so hard to get into (for aging people like myself and other friends/family) I would have repeated that build on this new FJ in a heartbeat.
The intent for this new 2014 build is reliability, durability and trail capable. And easier to get into
I spent considerable time thinking about my mod plan, and had almost everything on hand before the new FJ came in. The initial stage of this build was very fast. Most mods below completed from 11 Jul thru 5 Sep 2014. Of course, this was only a starting point, with many changes to follow...
THE PLAN
Frame/Body/Bumpers:
*full Fluid Film treatment of undercarriage
*transfer Aluminess bumper/Superwinch Rock95 to new FJ
*Shrockworks windshield reservoir in engine bay
*transfer all Springtail stuff to new FJ
*weathertech cabin floormats
*transfer toyota rear cargo rubber mat to new FJ
*Total Chaos link mount armor
*body mount chop with homemade front mudflaps
*Metal Tech step sliders with mini-bump
*Full Ricochet skids (minus gas tank) in gunmetal
*extend rear diff and locker breathers and front transmission and transfer case breathers Briareos's Build 2
*probably transfer rear LoD bumper/tire carrier to new FJ
*Baja rack, or maybe something else Frontrunner (also flat) in aluminum
*ADDED - Custom wind fairing for rack Briareos's Build 2
*ADDED - Tuffy Security Console with strut assist Briareos's Build 2
*ADDED - Toyota OEM receiver hitch and wiring harness
*ADDED - Expedition One rear bumper with swingout Briareos's Build 2
*ADDED - Toyota OEM formed aluminum rear belly pan
*ADDED - CalTrend neoprene seat covers
*ADDED - Modifed Rotopax mount/3-gal Rotopax can and Rugged Ridge stainless D-shackles added to bumper
*ADDED - 1/2" body lift
*REMOVED - Original vehicle frame (damaged in collision) Briareos's Build 2 and Briareos's Build 2
*ADDED - Entirely New Frame Briareos's Build 2
*REMOVED - Ricochet front HD skid and a-arm skids
*ADDED - Toyota TRD front aluminum skid
*ADDED - RCI Transition skid Briareos's Build 2
*ADDED - Front Runner roof rail kit (modified) Briareos's Build 2
Electrical Accessories:
*PIAA 540 ion crystal fog lights (transfer from old FJ)
*PIAA 520 driving lights (transfer from old FJ)
*Blue Sea fuze holder
*Daystar firewall boot
*ARB compressor in a toolbox (remounted to springtail side rack in back)
*Cobra all-in-one CB with Firestik antenna, fittings and cable mounted to Bandi mount
*Warn Power Interrupt solenoid for winch
*Various OTRATTW/Carling and Air-on-Board switches
*ADDED - Hella H71040801 Optilux 4" LED 12VDC Fog Lamp Kit in rear bumper
*ADDED - Toyota OEM roof light kit (minus airdam)
*ADDED - Hella Sharptone Horns Briareos's Build 2
*ADDED - Side (Hella H71020411 Optilux Mini Light Bar) and Rear (Front Runner 3" LED flood lamps) facing LED backup lights using Deutsch connectors and ODI through roof connector
*REMOVED - PIAA 520 driving lights
*ADDED - Hella Rallye 4000x driving lights
*REMOVED - Hella H71020411 Optilux Mini Light Bars (they kept filling up with water)
*ADDED - KAWELL® K6-6218 Off Road 18W CREE Ultra-thin 60 Degree LED Flood Light (although not a name brand, superior weather resistance and price vs. previous Hellas)
Front Suspension:
*Radflo 2.5" extended front coilovers (650 lb)
*Wheelers superbumps in front (with spacers)
*Total Chaos front upper arms (with bushings)
Rear Suspension:
*Metal Tech rear long travel springs (expedition weight - hoping to use LoD Bumper)
*Metal Tech long travel spec rear Radflo shocks
*Metal Tech bumpstop spacer
*Total Chaos rear lower arms (with modded bushings)
*Metal Tech rear upper links (with modded bushings)
*Crown stainless brake lines
*Icon rear panhard bar
*Skyjacker rear extended swaybar links
*Old Man Emu rear trim packer for driver side rear coil
*REMOVED - Metal Tech rear long travel springs (too much lift)
*REMOVED - Metal Tech long travel spec rear Radflo shocks (concern shocks would bottom out prematurely, even with bumpstop spacers)
*REMOVED - Metal Tech bumpstop spacer
*ADDED - Icon rear 2" lift rear Icon coils
*ADDED - *Icon VS 2" rear shocks and shinguards
*REMOVED - Icon VS 2" rear shocks and shinguards
*ADDED - Radflo rear 2.5" shocks (to help with new Exp 1 rear bumper)
*ADDED - Additional pair of OME trim packers and custom retainer on driver side coil bucket (to help with Exp 1 rear bumper) Briareos's Build 2
*REMOVED - Additional pair of OME trim packers and custom retainer on driver side coil bucket (not enough to fully compensate for Exp 1 rear bumper)
*ADDED - Custom rear coil spring spacers (to help with Exp 1 rear bumper) Briareos's Build 2
Wheels/Tires:
*285-70R17 Duratracs
*Method Mesh wheels (black of course)
*Modified ARP studs to go with wheels
*Mcgard lug nuts and locks (3/4 hex so better clearance between socket and wheel)
THE IMPLEMENTATION
Out with the old, in with the new on 12 Jul 2014 (The FJ, not the wife...)

EASY MODS
First mods were quick and easy: weathertech floormats, homemade paracord grab handles, and light-in-sight...



Then the work has to begin. Since this will likely be my last FJ, environmental protection is a higher priority...full fluid film treatment to exterior and INTERIOR of frame, and full Klasse paint sealant/glaze... PS - don't let the single can of fluid film fool you, I used half a case...

Then to re-install the Springtail system from my last FJ (got a little happy with orange gear ties/carabiners
)...

Metal Tech sliders with mini-bump and marine grip tape (which is not like sandpaper, it is bare feet friendly)...

ELECTRICAL ACCESSORIES
Firestick/Bandi mount install. I did completely sandblast, break all sharp edges, and repaint the bandi mount with rustoleum. The edges were so sharp I doubt the powdercoat would have made it through the winter without rust setting in...

Wired it through the door...

Where the antenna wire was bundled in with the compressor wiring. This is the ARB compressor that normally comes in a toolbox. It just so happens the mounting bracket for the toolbox is almost perfectly suited to this location.

Then while I was getting all the wiring out of the way, I installed the Warn Power Interrupt solenoid on the plastic radiator shroud. The plastic shroud is both close to the battery and offers extra insurance against an accidental chassis ground...

The the next question; how to get the rather large bundle of wires from the various switches and 8 gauge compressor power wire through the firewall?
Answer: a Daystar firewall boot. Wish I had found this for the previous build...

Then to fuze everything and hook it up in preparation for future bumper and lights...Blue Sea to the rescue to hold all the fuzes (30A for compressor, 1A for compressor switch, 2A for CB and 15A for fog lights). I also tapped the low beam trigger from the PIAA solenoid to the driver low beam fuze in the fuze box, rather than at the headlight wire, so much easier...


And finally, switches to control those future components...(again thanks to Ruebarb for his write up on how to install these in this panel...) I am actually running a double switch for the compressor, one up front, and the one that is part of the compressor mount. That way, I can prevent shifting cargo from accidently turning on the compressor by having a master kill switch up front. Important because I have the compressor wired to run on demand, not linked to ignition.

Update April 2015 - "air on board" winch power switch added, and I replaced the "old style" OTRATTW switches. The "new style" OTRATTW switches are easier to see at night without throwing a reflection in the driver side window, although I still think the "old style" ones were a better match to the FJ interior...

That build taught me many lessons, and overall I really liked my 2009 FJ - there is little substitute for effortlessly running 35" tires and the enjoyment of driving something far different from the norm. If it wasn't so hard to get into (for aging people like myself and other friends/family) I would have repeated that build on this new FJ in a heartbeat.
The intent for this new 2014 build is reliability, durability and trail capable. And easier to get into
I spent considerable time thinking about my mod plan, and had almost everything on hand before the new FJ came in. The initial stage of this build was very fast. Most mods below completed from 11 Jul thru 5 Sep 2014. Of course, this was only a starting point, with many changes to follow...
THE PLAN
Frame/Body/Bumpers:
*full Fluid Film treatment of undercarriage
*transfer Aluminess bumper/Superwinch Rock95 to new FJ
*Shrockworks windshield reservoir in engine bay
*transfer all Springtail stuff to new FJ
*weathertech cabin floormats
*transfer toyota rear cargo rubber mat to new FJ
*Total Chaos link mount armor
*body mount chop with homemade front mudflaps
*Metal Tech step sliders with mini-bump
*Full Ricochet skids (minus gas tank) in gunmetal
*extend rear diff and locker breathers and front transmission and transfer case breathers Briareos's Build 2
*probably transfer rear LoD bumper/tire carrier to new FJ
*Baja rack, or maybe something else Frontrunner (also flat) in aluminum
*ADDED - Custom wind fairing for rack Briareos's Build 2
*ADDED - Tuffy Security Console with strut assist Briareos's Build 2
*ADDED - Toyota OEM receiver hitch and wiring harness
*ADDED - Expedition One rear bumper with swingout Briareos's Build 2
*ADDED - Toyota OEM formed aluminum rear belly pan
*ADDED - CalTrend neoprene seat covers
*ADDED - Modifed Rotopax mount/3-gal Rotopax can and Rugged Ridge stainless D-shackles added to bumper
*ADDED - 1/2" body lift
*REMOVED - Original vehicle frame (damaged in collision) Briareos's Build 2 and Briareos's Build 2
*ADDED - Entirely New Frame Briareos's Build 2
*REMOVED - Ricochet front HD skid and a-arm skids
*ADDED - Toyota TRD front aluminum skid
*ADDED - RCI Transition skid Briareos's Build 2
*ADDED - Front Runner roof rail kit (modified) Briareos's Build 2
Electrical Accessories:
*PIAA 540 ion crystal fog lights (transfer from old FJ)
*PIAA 520 driving lights (transfer from old FJ)
*Blue Sea fuze holder
*Daystar firewall boot
*ARB compressor in a toolbox (remounted to springtail side rack in back)
*Cobra all-in-one CB with Firestik antenna, fittings and cable mounted to Bandi mount
*Warn Power Interrupt solenoid for winch
*Various OTRATTW/Carling and Air-on-Board switches
*ADDED - Hella H71040801 Optilux 4" LED 12VDC Fog Lamp Kit in rear bumper
*ADDED - Toyota OEM roof light kit (minus airdam)
*ADDED - Hella Sharptone Horns Briareos's Build 2
*ADDED - Side (Hella H71020411 Optilux Mini Light Bar) and Rear (Front Runner 3" LED flood lamps) facing LED backup lights using Deutsch connectors and ODI through roof connector
*REMOVED - PIAA 520 driving lights
*ADDED - Hella Rallye 4000x driving lights
*REMOVED - Hella H71020411 Optilux Mini Light Bars (they kept filling up with water)
*ADDED - KAWELL® K6-6218 Off Road 18W CREE Ultra-thin 60 Degree LED Flood Light (although not a name brand, superior weather resistance and price vs. previous Hellas)
Front Suspension:
*Radflo 2.5" extended front coilovers (650 lb)
*Wheelers superbumps in front (with spacers)
*Total Chaos front upper arms (with bushings)
Rear Suspension:
*Metal Tech rear long travel springs (expedition weight - hoping to use LoD Bumper)
*Metal Tech long travel spec rear Radflo shocks
*Metal Tech bumpstop spacer
*Total Chaos rear lower arms (with modded bushings)
*Metal Tech rear upper links (with modded bushings)
*Crown stainless brake lines
*Icon rear panhard bar
*Skyjacker rear extended swaybar links
*Old Man Emu rear trim packer for driver side rear coil
*REMOVED - Metal Tech rear long travel springs (too much lift)
*REMOVED - Metal Tech long travel spec rear Radflo shocks (concern shocks would bottom out prematurely, even with bumpstop spacers)
*REMOVED - Metal Tech bumpstop spacer
*ADDED - Icon rear 2" lift rear Icon coils
*ADDED - *Icon VS 2" rear shocks and shinguards
*REMOVED - Icon VS 2" rear shocks and shinguards
*ADDED - Radflo rear 2.5" shocks (to help with new Exp 1 rear bumper)
*ADDED - Additional pair of OME trim packers and custom retainer on driver side coil bucket (to help with Exp 1 rear bumper) Briareos's Build 2
*REMOVED - Additional pair of OME trim packers and custom retainer on driver side coil bucket (not enough to fully compensate for Exp 1 rear bumper)
*ADDED - Custom rear coil spring spacers (to help with Exp 1 rear bumper) Briareos's Build 2
Wheels/Tires:
*285-70R17 Duratracs
*Method Mesh wheels (black of course)
*Modified ARP studs to go with wheels
*Mcgard lug nuts and locks (3/4 hex so better clearance between socket and wheel)
THE IMPLEMENTATION
Out with the old, in with the new on 12 Jul 2014 (The FJ, not the wife...)

EASY MODS
First mods were quick and easy: weathertech floormats, homemade paracord grab handles, and light-in-sight...



Then the work has to begin. Since this will likely be my last FJ, environmental protection is a higher priority...full fluid film treatment to exterior and INTERIOR of frame, and full Klasse paint sealant/glaze... PS - don't let the single can of fluid film fool you, I used half a case...

Then to re-install the Springtail system from my last FJ (got a little happy with orange gear ties/carabiners

Metal Tech sliders with mini-bump and marine grip tape (which is not like sandpaper, it is bare feet friendly)...

ELECTRICAL ACCESSORIES
Firestick/Bandi mount install. I did completely sandblast, break all sharp edges, and repaint the bandi mount with rustoleum. The edges were so sharp I doubt the powdercoat would have made it through the winter without rust setting in...

Wired it through the door...

Where the antenna wire was bundled in with the compressor wiring. This is the ARB compressor that normally comes in a toolbox. It just so happens the mounting bracket for the toolbox is almost perfectly suited to this location.

Then while I was getting all the wiring out of the way, I installed the Warn Power Interrupt solenoid on the plastic radiator shroud. The plastic shroud is both close to the battery and offers extra insurance against an accidental chassis ground...

The the next question; how to get the rather large bundle of wires from the various switches and 8 gauge compressor power wire through the firewall?
Answer: a Daystar firewall boot. Wish I had found this for the previous build...

Then to fuze everything and hook it up in preparation for future bumper and lights...Blue Sea to the rescue to hold all the fuzes (30A for compressor, 1A for compressor switch, 2A for CB and 15A for fog lights). I also tapped the low beam trigger from the PIAA solenoid to the driver low beam fuze in the fuze box, rather than at the headlight wire, so much easier...


And finally, switches to control those future components...(again thanks to Ruebarb for his write up on how to install these in this panel...) I am actually running a double switch for the compressor, one up front, and the one that is part of the compressor mount. That way, I can prevent shifting cargo from accidently turning on the compressor by having a master kill switch up front. Important because I have the compressor wired to run on demand, not linked to ignition.

Update April 2015 - "air on board" winch power switch added, and I replaced the "old style" OTRATTW switches. The "new style" OTRATTW switches are easier to see at night without throwing a reflection in the driver side window, although I still think the "old style" ones were a better match to the FJ interior...
