100 Series Long Travel Options 2025

[OffRoadRN]

There was a lot of discussion on Bamacruiser's Long Travel #ih8torsionbars post regarding a couple new options for 100 Series long travel that are coming to the market.

The first is from Kamono Concepts (@filthy4r on IG, kamonoconcepts.com). Looks like there are more pictures of actual fabrication on IG vs just renderings on the website. There are multiple kits available for different vehicles on the website.

Samson100 posted the following on 2/14

4 - 6 weeks away from producing a long travel kit for the 100 series / LX 470. The kit will add +2 width, push the suspension +1 forward, and will allow for coilovers, bypasses (TBD if there is room for them), and bump stops.

He has quoted me $5.8k for a pre-welded kit (DIY kit is approx. $4.4k) including new CVs and knuckles (as well as UCAs, LCAs, shock tower, and all other necessary hardware). Note, this does not include the cost for shocks.

It will be going up for pre-sale in the next week or so.

The second upcoming option is from Dave at Savage Fab (@savage_fab). He has a good number of photos of his design so far, including the custom lower control arm build. Savage fab has reportedly built buggies and other LT kits as well, which you can see on IG. Dave is currently working on a batch of 10 kits, and will be using custom CV axles, but will possibly be using RCV in the future it looks like?

Regarding the price of the Savage Fab kit, samson100 said:

$6.5k including axles (note, the axles aren’t RCV; going to take a couple weeks to get those). Shocks will vary depending on what you want.

As of 3/3 it sounds like there are a few spots left on the first 10 kits. DM Dave on IG to book a call if you are interested.

 

[OffRoadRN]

 

[GTV]

That other thread got me thinking…

If 2nd gen Tundra axle shafts do in fact fit 100 series CV joints that would be an easy and inexpensive starting point as they are ≈2” longer.
Custom upper and lower control arms would of course need to be fabricated but keep the torsion bars in place for the sake of simplicity. At the same time the wheel could easily be placed forward to create additional tire clearance at the firewall.
Lengthen the inner tie rods, longer brake lines, extend the wires for the wheel speed sensors.
Regular 100 series shocks (long travel versions), even AHC could still be utilized.
And… done. It wouldn’t offer the same travel as a coil over but it would be an improvement and it would be “bolt on”.

To take it a step further- Custom control arms might be designed to accept 200 series/Tundra steering knuckles along with their sealed bearing hubs. Larger 2nd gen Tundra brakes would be a direct fit.

 

[OffRoadRN]

That’s a pretty good idea. Another DIY option is to weld in a section from a 2nd gen Tundra. Thats what “Russian Alex” did. I don’t know the guy, just DM’d on IG (@carpenter_by_night).

“I grafted in a section of a 2nd gen tundra frame to my front end which allowed me to bolt on all tundra suspension and 200 steering rack. Custom cv axles.

I’m running standard length tundra arms which made the front end 2.5” wider per side and doubled the wheel travel of a standard 100.
The axles are actually 3rd gen tundra axles that were shortened 1” and resplined to accept the factory 100 inner cv joint to fit into the diff. Have not broken anything yet.

Engine mounts didn’t need any work other than just needed a 3/16” spacers between engine and mount brackets. Needed just a bit of clearance at the steering rack.

This swap really hit the spot - it’s crazy capable, super beefy and drives like a car on-road. Plus it’s pretty unique and feels more like it should have been like this from the factory. Oem+”

 

[sanya]

I’m half russian Alex with the above 100. I wouldn’t say that what I did is a simple DIY option. I think doing what Dave (savage fab) is doing is a lot less work and quite a bit simpler. I just didn’t trust myself to nail the suspension geometry. I felt more comfortable just transferring over what Toyota designed over to my truck since I’ve been a collision tech for 23 years and cutting cars apart and putting them back together is my bread and butter.

Also keep in mind that you loose abs/atrac with the tundra swap since the 100 abs ring and tundra tone rings are completely different.

You do gain the beefier steering, axles and the nice sealed wheel bearings.

 

[Exiled]

Although this is way past the way I use my 100, I have been watching this trend towards bigger tires, improved suspensions and much more extreme trail use for 100s with great interest. I *never* thought I'd see a 100 running anything bigger than 35's! The use of OEM Tundra components seems like the way to go for parts availability vs. full custom, but that may be my Third World-born paranoia thinking out loud.

 

[MongooseGA]

I’m half russian Alex with the above 100. I wouldn’t say that what I did is a simple DIY option. I think doing what Dave (savage fab) is doing is a lot less work and quite a bit simpler. I just didn’t trust myself to nail the suspension geometry. I felt more comfortable just transferring over what Toyota designed over to my truck since I’ve been a collision tech for 23 years and cutting cars apart and putting them back together is my bread and butter.

Also keep in mind that you loose abs/atrac with the tundra swap since the 100 abs ring and tundra tone rings are completely different.

You do gain the beefier steering, axles and the nice sealed wheel bearings.

I don't care what you say, you're always going to be Russian Alex to me.

Just like Crossfit Zach will always be, even though I heard he doesn't do Crossfit anymore.

 

[samson100]

As an update for folks, I am going to be the guinea pig here and am headed up to Washington in early April to have the Savage_Fab kit installed on my 100 series. Already got my Kings (2.5 x 8 inch coilovers w/ RRs and compression adjustments). Now just to figure out what I’m doing for rear suspension.

 

[OffRoadRN]

As an update for folks, I am going to be the guinea pig here and am headed up to Washington in early April to have the Savage_Fab kit installed on my 100 series. Already got my Kings (2.5 x 8 inch coilovers w/ RRs and compression adjustments). Now just to figure out what I’m doing for rear suspension.

Hell yeah that’s exciting, I’m happy for you! I can’t wait to see it in action.

 

[Escape Artist]

This is considerably more affordable than a solid axle conversion. And I would be able to keep my front locker … i’m kicking myself for rebuilding my entire AHC system though. Wish there was a way to convert one of the hydraulic shocks to a coil over. Just not a big fan of torsion bars.

 

[GTV]

This is considerably more affordable than a solid axle conversion. And I would be able to keep my front locker … i’m kicking myself for rebuilding my entire AHC system though. Wish there was a way to convert one of the hydraulic shocks to a coil over. Just not a big fan of torsion bars.

I believe I saw pics of a Dakar 100 series on here that had coil overs along with the torsion bars...

 

[samson100]

As an update, life got in the way so I wasn't able to make it up to WA from Los Angeles. With that being said, Dave at Savage Fab is still making good progress, and the prototype is almost complete - see below for some photos from last week. With the passenger side being largely complete, he is moving on to the drivers side this week. From there, he will be getting the prototypes put into CAD and then will have all the metal cut via water jet. Based off the current timeline, Dave is supposed to deliver the first and second set to Zach and me, respectively, by early to mid May.

Note, the sway bar bracket is only for the prototype / jig to ensure everything is aligned properly and won't be in the final version.

 

[TysonLC]

As an update, life got in the way so I wasn't able to make it up to WA from Los Angeles. With that being said, Dave at Savage Fab is still making good progress, and the prototype is almost complete - see below for some photos from last week. With the passenger side being largely complete, he is moving on to the drivers side this week. From there, he will be getting the prototypes put into CAD and then will have all the metal cut via water jet. Based off the current timeline, Dave is supposed to deliver the first and second set to Zach and me, respectively, by early to mid May.

Note, the sway bar bracket is only for the prototype / jig to ensure everything is aligned properly and won't be in the final version.

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any update on this? its been awhile since ive seen anything on the savage fab page.

 

[samson100]

any update on this? its been awhile since ive seen anything on the savage fab page.

It has taken longer than expected for sure, but Dave has made great progress, and the kit is like 95% complete. He has been providing updates via text to the group that has purchased the kit. Likely looking at having my kit in hand by the end of August.

 

[Yung4Lo]

It has taken longer than expected for sure, but Dave has made great progress, and the kit is like 95% complete. He has been providing updates via text to the group that has purchased the kit. Likely looking at having my kit in hand by the end of August.

How’s it looking?

 

[samson100]

How’s it looking?

Things are looking great! Dave at Savage Fab is almost done installing the first kit on his vehicle and has been concurrently welding up parts for the other kits. So far, shock hoops, axles, and most of the small bits have been manufactured. Once his kit is installed and tolerances are confirmed (targeting completion of this by [Friday]), he will weld up the upper and lower arms for the remaining kits. I'll post the pictures that Dave has been sending me. While it has taken longer than we all have wanted, it has resulted in a much better product overall.