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On a recent trip to the mountains (Margaret Lake run) my FJ fell through the ice and bent a spindle. I talked to a few members here on the site and they suggested putting gussets on the spindles to strengthen them up. The options available eliminated the sway bar link mounting holes, hence no sway bar. My buddy Fred and I took a look at what was out there and decided to design our own gusset system. We decide to use 4"X4"X 1/4" angle to cut our gussets out of. We located our gussets to the outside edge of the spindle and cut a relief hole to enable installing the sway bar links. This all took a Saturday afternoon and a lot of welding rod and some time with a plasma cutter. The pictures are as follows;

http://www.fjcruiserforums.com/gallery/data/500/medium/bent.JPG

http://www.fjcruiserforums.com/gallery/data/500/thumbs/new_bent.JPG

http://www.fjcruiserforums.com/gallery/data/500/thumbs/repair1.JPG

http://www.fjcruiserforums.com/gallery/data/500/thumbs/repair2.JPG

http://www.fjcruiserforums.com/gallery/data/500/thumbs/both_modded.JPG

http://www.fjcruiserforums.com/gallery/data/500/thumbs/installed.JPG

Sorry about not having the pics here but I wanted to get them up as soon as possible. I have more pics and if you want any info just ask here and I would be happy to answer any of your questions.
 

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Your first picture looks fine. the others are so small I can not see them. Whats up with that?
 

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Doesn't look to bad. Can't believe you bent your spindal though that is just nuts.
 

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WOW, Jesuha, what ever you did, Thanks for making them larger. I can see them. WOOT!
 

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If it helps here are the Total Chaos spindle gussets that Demello put on for me. For those who can't find a Canadian welder, they're available at TC for about $130 I think.
 

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Discussion Starter #13
Looks beefy. Glad the spindles and gussets worked out for you. I love seeing pieces of my FJC live on. :D


Thanks for the parts an yes they are much stronger now and I can still use my sway bar.

To all those that can't believe I bent a spindle.......we werent going fast or doing anything crazy....just heading out of the trail system back to the road in the dark....it didn't take much, but was a lot grief getting it home.

...with this mod I understand the my upper and lower control arms are now the weak point....they will be replaced in the future as cash permits.........
 

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Great job Mark, looks alot stronger.
 

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If it helps here are the Total Chaos spindle gussets that Demello put on for me. For those who can't find a Canadian welder, they're available at TC for about $130 I think.
$40 pr on their website... :)
 

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I'm a major fan of anyone doing garage-fab, so BIG HI-FIVE there!

That TC makes a part to do this, suggests that there's an at-risk group to sell them to.

Who would typically bend a spindle arm? Baja style prerunners??

This is breakage that I've not seen. I'm impressed. ;)
 

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EDIT: found them - they're listed under '05-'08 Taco's not FJC in accessories, five items down from the top.

Could you put a link up for the page on the chaosfab site that has these parts? I've been there, searched, can't find. Thanks.
Good eye!

That TC makes a part to do this, suggests that there's an at-risk group to sell them to.

Who would typically bend a spindle arm? Baja style prerunners??

This is breakage that I've not seen. I'm impressed. ;)
There have actually been a couple of slow-speed spindle failures, stagecoachco can attest to one of them. I still don't think we know why his bent going less than 10mph, but I'm guessing it can be the result of fatigue since some of us put them under more stress than most, even at low speeds.
 

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Who would typically bend a spindle arm? Baja style prerunners?? This is breakage that I've not seen. I'm impressed. ;)
The Tacoma prerunners tend to bend spindles on a regular basis. The stock spindles just aren't strong enough to handle leaping a truck off a sand dune. :)
 
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