[TCao]

Monument Valley, AZ Nov 2007 (after the Kokopelli Trail Expedition with the Toyota Trails Team)

Welcome to my build-up/journal page, summarizing the current modifications on my 2007 Titanium Metallic Toyota FJ Cruiser with MT6 transmission. More details and photographs can be found by clicking on the links.​

FACTORY

Factory options: Upgrade Package 1 (UP), Convenience Package (CQ), TRD exhaust, factory sliders, tire cover, side curtain airbags, floormats

Order date: 7 Jan 2006

Build date: Feb 2006

Delivery date: 25 Mar 2006 (official launch date in the US)

BUILD PURPOSE

Overland expedition vehicle

Current Configuration

Anza-Borrego Desert State Park, CA

LIST OF MODIFICATIONS​

ENGINE/DRIVETRAIN

Safari snorkel (installation)
AFE Pro Dry S air filter, PN 31-10114 (drop-in) (maintenance)
Mobil1 synthetic engine oil, 5W30
Redline synthetic oil for all differentials and manual transmission, 75W90 (PN 57904) and 75W90NS (PN 58304)
Relocated rear differential breather

SUSPENSION/TIRES/WHEELS/BRAKES

Front:
2.5” DIA King coilovers, 550 lb/inch spring rate, 5.5-inch shock travel (custom build with 1/4" shorter internal spacer), compression adjuster on remote reservoirs
2.0" DIA King hydraulic bump stops, 1.5-inch travel (shortened from 2.0" travel)
Total Chaos Upper Control Arms, PN 96504 (installation) (TC UCA's maintenance)
Total Chaos Lower Control Arms, PN 86500 (details)
Total Chaos shock tower gussets, PN 59651 (installation)
Total Chaos HD spindle gussets, PN 59698-SB (compatible with front sway bar) (installation) (photos)
Wheel Travel: 8.5" with 285/75R16 BFG AT tires
Brakes: EBC Sport rotors (GD 7237) and Green Stuff 7000 series pads (DP 71657)
Total Chaos stainless steel braided brake hoses, PN 86330 (2" longer) (DOT approved)
Limit straps with adjustable clevis (12" long) (photos)
Anti sway bar removed

Rear:
2.5” DIA King shocks, compression adjuster on remote reservoirs (installation) (Shock boots)
Custom Coil Spring Specialties springs (1" lift and 210 lb/inch spring rate)
2.0" DIA King hydraulic bump stops, 2-inch travel (details)
Total Chaos rear lower links, PN 86400L (9.5 lb each) (details)
Total Chaos rear upper links, PN 86400U (5.5 lb each)
Total Chaos panhard bar, PN 86400P (12 lb)
Addco rear sway bar, PN 2301 (22.2mm diameter, 9 lb) (installation)
Wheel Articulation: 13.25" (with rear swaybar disconnected) (details)
Brakes: EBC Sport rotors (GD 7161) and Toyota OE pads (PN 04466-60090)
Total Chaos stainless steel braided brake hoses, PN 97330 (2.5" longer) (DOT approved)

King suspension

Wheels/Tires Combination 1 (SOLD)
Tires: BF Goodrich All Terrain TA, 285/70R17
Wheels: factory FJC steel, 7.5 x 17 with 4.84" BS
Wheel/Tire weight = 102 lbs

Wheels/Tires Combination 2 (SOLD) (photos with old KM)
Tires: BF Goodrich Mud Terrain KM2, 255/85R16 (old KM details) (new KM2 details)
Wheels: factory FJC TRD alloy, 7.5 x 16 with ET15 (PN PT904-35070) with OMF beadlock conversion (details)
Wheel/Tire weight = 84 lbs (measured)

Wheels/Tires Combination 3 (Current)
Tires: BF Goodrich All Terrain TA, LT285/75R16 E 126/123Q, 56 lbs (details)
Wheels: Level 8 Mk6, 8 x 16 with ET0 (4.50" backspace), product code 16138, 22 lbs (details)
Wheel/Tire weight = 78 lbs (measured)

Body mount modification by DeMello

O&B anti swaybar collars (removed with front sway bar) (details)

ARMOR

DeMello tube bumper, 57 lbs (measured) (details)
DeMello IFS skid plate, 50 lbs (measured)
DeMello custom hybrid sliders (details)
DeMello reinforced LCA mounts, front and rear (photos of rear mount)
DeMello rear bumper with Acro back up lights
DeMello offroad tow hitch, 9.6 lbs (measured) (details)

AUXILLIARY LIGHTS

Aeroflow headlight covers, clear
Lightforce 240 XGT driving lights (2), bumper mounted
Hella Micro DE projector fog lights (2), bumper mounted
Hella FF75 driving lights (4), roof mounted (photos) (removed with roof rack)
PIAA 1500 flood lights (2), roof mounted (facing aft) (photos) (removed with roof rack)

RECOVERY GEAR

Warn M8000 winch (uninstalled for now to reduce weight over front axle)
Albright sealed solenoid (not installed)
95 ft Viking 5/16" synthetic winchline with safety thimble (removed with winch)
D shackles (3)
Viking Delrin fairlead
ARB snatch block
ARB tree strap
ARB X Jack
SuperStrap 1" x 20' tow strap
ARB VKMA air compressor (On-Board Air system) (installation)
Tire repair kit
Gloves

COMMUNICATION/ELECTRONICS

Yaesu FT-7800R 2m/70cm amateur band transceiver (details)
Yaesu YSK-7800 separation kit (remote mic)
Laird Technologies/Antenex ETRA 1440 (installation)
Yaesu VX-6R 2m/70cm amateur band hand transceiver
Midland 75-822 citizen band transceiver (details)
Firestick II antenna, 2-ft no ground plane mount kit
bandi mount
NMO roof mount, Larsen (details)
Comet SBB-1 2m/70cm antenna (roof rack mounted) (details)
Diamond NR-770HB 2m/70 cm antenna (bumper mounted) (details)
Kenwood DNX-7100 stereo/GPS head unit
Kenwood KCA-BT300 Bluetooth adaptor (details)
Infinity Primus PR6500cs component door speakers (details)
Infinity Reference 1060W subwoofer with custom subwoofer box (details)
Rockford Fosgate Punch P450.4 4-channel amplifier
PAC Audio steering wheel control adaptor
USB Mass Storage Device, 16GB (music)
Battery Plus X2 dual purpose (starting/deep cycle) primary battery, model SLI27FAGMDP (67 lb) (details)
Sears Diehard Platinum PM-2 auxiliary battery (53 lb) (Aux Battery Version 2.0 installation)
National Luna Intelligent Solenoid battery isolator/combiner (1.5 lb with bracket)
MFJ-281 external speaker (details)
Audiovox rear view camera (details)

MISCELLANEOUS MODIFICATIONS/EQUIPMENT

Sparco R505 seats with Sparco seat bases (Installation details: Part I, Part II, Part III)
Schroth Rallye 3 four-point safety belts(Chime and Warning Disable)
Tuffy Products center console insert (PN 144) (details)
Iron Mountain Performance gray shift knobs
Scangauge II (details)
Blue Sea fuse box (2) with 80A Maxi fuses (details)
Hella 4-gang relay block (installation)
Hella 4-gang fuse block (installation)
Gobi custom shorti rack with antenna mount (details) (removed)
Scepter 20-liter fuel canister
Scepter 20-liter water canister
Spares (CV assembly, CV boot kit, serpentine belt, radiator hoses, oil filter, cabin air filter)
First Aid bag
Bug-out bag
Tool kit
Glock folding shovel with saw
Gerber axe
Trico NeoForm windshield wiper blades
Sunsei SE-400 solar charger, 400mA @ 15V
ARB MT 45 fridge/freezer with Polytherm baskets (details)
ARB fridge insulated transit cover
Engel Slide (all steel) (details) (updates)
12V Power Outlet for ARB fridge (Marinco)
12V Power Outlet for CB (Marinco)
Custom storage box/sleeping platform (details)
Custom auxiliary battery box mount and hold down, 6061-T6 aluminum (2.5 lb)
Unique Metal Products engine oil box (4 quarts) (details)
Load Tamer cargo net
Thule 7022 Go Box
Ratchet tie-down straps
Adjustable bungee cords
Amerex B500T fire extinguisher
Amerex 807 heavy duty fire extinguisher bracket
Emergency hammer/seatbelt cutter (update)
Dynamat Xtreme + Neoprene foam noise barrier (one bulk pack ~ 32 lbs) (details)
Folding table for rear door (details)
Back Door Interior Lock/Unlock Switches (details)
Back Door Interior Handle (details)
Detachable Petzl maplight (details)

TRUSTED VENDORS
DeMello Off Road, Corona, CA
Total Chaos Fabrication, Corona, CA
King Off-Road Shocks, Garden Grove, CA
OMF Performance Products, Riverside, CA
TRDParts4U (Toyota of Dallas), Dallas, TX

Maintenance

Total Chaos UCA Uniball maintenance

Cleaning engine air filter and cabin air filter

100k mile service (include fluid change for differentials, transfer case, and manual transmission)

PHOTO GALLERY "The Way We Were"​

Anza-Borrego camping trip, Apr 2006 (one week old and no mods yet)

Fabfours bumper installed, Jul 2006 (this bumper has been replaced by the DO tube bumper after it was damaged in an accident in Homer, AK) (gory details)

Borregofest I, Anza-Borrego desert state park, Oct 2006

Steelbender, Moab springfling, Moab UT, Apr 2007 (photo courtesy of stagecoachco)

Alpine loop, First Annual FJ Cruiser Summit, Ouray CO, Jul 2007

Crossing the Artic Circle, Dempster highway, YT Canada, Jul 2007

Dalton highway with Trans Alaska pipeline in background, Alaska, Aug 2007

Goin' swimmin', Kokopelli Trail Expedition, Nov 2007 (photo courtesy of James, EC FJCTT)

The Serpent and the FJC, Galleta Meadows, Borrego Springs

2008 Kokopelli Trail Group Photo

Maiden Voyage: 2007 Alaska

2007 Kokopelli Trail Expeditionhttp://www.fjcruiserforums.com/forums/731714-post212.html

2008 Annapurna Circuit Trek

 

[rich_4]

looking great.

any comments on the total chaos UCA's?

 

[TCao]

looking great.

any comments on the total chaos UCA's?

The TC UCAs are a huge improvement over the factory units. Over 13,000 miles of use so far and no squeaks or issues.

 

[Fjamming]

Nice write up Thong. Looks like it has improved even more since Springfest. Could you elaborate on how the TC UCA has improved over the factory unit?

 

[jeshua]

Looking good T.

I love that dirty FJ picture of yours one of my favorite FJ pictures.


What came to pass at the body shop?

 

[LandCruiserSteve]

I had the privilege and honor of seeing your great rig and its respective mods in Ouray, and I'm still in awe of your creation.

Great job, Thong!!

 

[TrAiLbUs1]

Looking good Thong...good write up

 

[Dragon]

Great write up.
Great photos.
Great truck.

You're an asset to this community! Thanks for taking the time to share your ride with us.

 

[TCao]

Nice write up Thong. Looks like it has improved even more since Springfest. Could you elaborate on how the TC UCA has improved over the factory unit?

Tony:

My primary reasons for upgrading to the Total Chaos UCAs are improved steering response and durability. The King coilovers are adjusted for a 2-inch net lift with the Fabfours bumper and winch (net gain of 123 lbs on the front axle compared to OEM plastic bumper) so I did not need after market UCAs for correcting caster. I have the King coilovers with the OEM UCAs for almost 7,000 miles and did not observe any unusual tire wear or steering wandering.

The OEM UCAs are steel stampings with an open cross section (the bottom seams are not welded together); the TC UCAs are weldments with a tubular cross section which are structurally stiffer and can handle much higher bending and torsion loads. In addition, the Teflon-lined spherical bearings (uniballs) in the TC UCAs are larger than the OEM ball joints and can handle larger loads and also have more angular travel providing slightly more articulation (less binding). And lastly, the urethane bushings provided with the TC kit are stiffer than the OEM rubber bushings; these stiffer bushings help maintain the front geometry for more precise steering response. IMO, the TC UCAs are more durable since they have higher structural rigidity (chromoly tubing and larger cross-sectional moment of inertia) and better finishes to resist corrosion (stainless steel or zinc-plated hardware and powder coating with clear coat).

One of the small side benefits with the TC UCAs is easier trail repairs. With the OEM ball joints, you'd need a ball joint separator or fork if you need to disassemble the UCA from the spindle. With the TC UCAs the 9/16" spindle bolt can be removed with standard sockets (and a big wrench since the nut is torqued down to 100 ft-lbs).

The downside to after market UCAs such as the Total Chaos is more maintenance. The bushings require regular application of synthetic grease and the uniballs need a few squirts of Tri-Flow now and again.

Thong

edit: added photo of OEM UCA for comparison.

 

[TCao]

Looking good T.

I love that dirty FJ picture of yours one of my favorite FJ pictures.


What came to pass at the body shop?

Thanks Josh. I dropped off my FJ last week and the initial repair estimate is 3 weeks. My insurance company (AAA) allows me to use another after market front bumper of equivalent quality (i.e. cost). So, I ordered a custom tube bumper from Jason DeMello the same day I dropped off the truck; this tube bumper should be about half the weight of the Fabfours. I also ordered two Lightforce 240 GTX driving lights to replace the current IPF 960. Hopefully, I'll be ready for Borregofest II.

 

[TCao]

I had the privilege and honor of seeing your great rig and its respective mods in Ouray, and I'm still in awe of your creation.

Great job, Thong!!

Thank you Steve. Your post on your storage box inspires me to design and build my version. I'll post up photos when I got the truck back.

 

[TCao]

Looking good Thong...good write up

Thanks Jake.

 

[TCao]

Great write up.
Great photos.
Great truck.

You're an asset to this community! Thanks for taking the time to share your ride with us.

Thank you Bill. I'm still planning the Nova Scotia trip and I'll keep you informed.

 

[uphill]

I especially enjoyed your Alaskan Trip posting. It really gave me a yearning to follow in your footsteps.

Thanks for posting your build-ups. One question: If you had it to do over again, would you install the aux. battery? I've been swayed in both directions (add/don't add) and would like your thoughts on the subject.

 

[wesayso]

Wowsers! Nice rig.

 

[TCao]

I especially enjoyed your Alaskan Trip posting. It really gave me a yearning to follow in your footsteps.

Thanks for posting your build-ups. One question: If you had it to do over again, would you install the aux. battery? I've been swayed in both directions (add/don't add) and would like your thoughts on the subject.

If I have to do it over again, I'd still install an aux battery except it won't be on the right inner fender. I'm considering relocating the aux battery inside the FJ. I have already removed the rear seats and build a storage box very similar to Steve's design and that's where I would locate the Optima (passenger side). I like to travel to very remote locations and having an aux battery is a necessity. I also listed the Sunsei battery charger in the misc equipment. This charger works great for times when I want to camp in the same locations for a few days and not drive the FJ. The solar charger provides just enough charge to maintain the Optima battery with the ARB fridge running. Dirty Parts has the only kit I know of so far for our FJC.

 

[TCao]

Wowsers! Nice rig.

Thanks. I'm glad you like my Fantastic Journeymobile.

 

[Fjamming]

Thong, thanks for the detailed analysis of the TC UCA. Much appreciated.

 

[jeshua]

Thanks Josh. I dropped off my FJ last week and the initial repair estimate is 3 weeks. My insurance company (AAA) allows me to use another after market front bumper of equivalent quality (i.e. cost). So, I ordered a custom tube bumper from Jason DeMello the same day I dropped off the truck; this tube bumper should be about half the weight of the Fabfours. I also ordered two Lightforce 240 GTX driving lights to replace the current IPF 960. Hopefully, I'll be ready for Borregofest II.

Very nice, and those lights are going to be sick, I want them.

 

[Fjamming]

Thong, just realized you mentioned the XGTs. I was spoke to Wil earlier this week (Sierra Expeditions) about the difference between the XGT and Blitz. I originally was going with the XGTs, but he swayed me towards the Blitz. The XGTs are a little bit brighter then the Blitz, but they are not adjustable. The Blitz can be adjusted for different degree of light spread. They are also more driving light like then pencil. XGTs will be great for open desert bombing, but the Blitz should be better for general trails and rocks. Both lights are extremely bright. Brightest non HIDs in the market. You may have already know that but I thought I'd share in case others are thinking about them.