Build Stretched 1-Ton FJ40

[peesalot]

With my axle being stock width I may need to go beyond flush with inner edge. Not to concerned with frame bracing around tower as I agree with cage & body only carrying gear ( no suspension forces ) its fine IMO. I will run a bar across top of towers & build a gear shelf off that, hopefully still be able to open fridge lid.
Getting axle truss on a black friday deal.

 

[Mike Shull]

With my axle being stock width I may need to go beyond flush with inner edge. Not to concerned with frame bracing around tower as I agree with cage & body only carrying gear ( no suspension forces ) its fine IMO. I will run a bar across top of towers & build a gear shelf off that, hopefully still be able to open fridge lid.
Getting axle truss on a black friday deal.

I like that idea. I wasn’t too clear about what I wouldn’t do again. Ha. I’d notch the frame but I would engineer some better bracing from behind the frame before I added the tower. What I did seems strong but it is ugly and I know that I can do better. I added my c channel behind the notch after the notch was in place and I think that it would have been stronger and easier to add before the notch was in place.

 

[Mike Shull]

I’ve got the plasma cutter out again

 

[Ditcherman]

I’ve got the plasma cutter out again

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That’s a big deal, knocking them off the list already!

 

[Mike Shull]

That’s a big deal, knocking them off the list already!

You know it!

 

[peesalot]

My Plasma cutter is a Porter Cable sawzall

 

[Mike Shull]

Done!

 

[Mike Shull]

Here is a video of me building the skid plate. I will build the fuel tank skid next weekend.

Fabricating a Custom FJ40 Skid Plate

 

[Mike Shull]

Here is a video of me building the skid plate. I will build the fuel tank skid next weekend.

Fabricating a Custom FJ40 Skid Plate

Bob @devo, you are featured again in this one. Ha.

 

[devo]

It’s good to see myself again, thanks!
I dig the fab vid too. Nice shop you have there. You’re quite talented.

I say more trails and more spotting in 2026 Mike .

 

[Mike Shull]

Another item is checked off of the list! The fuel tank skid is done.

 

[Mike Shull]

I thought that some of you would rather see pictures than watching the video. I am very happy with the results and can’t wait to venture back into Utah to test out the new equipment.

 

[Blackknight1]

Here is a video of me building the skid plate. I will build the fuel tank skid next weekend.

Fabricating a Custom FJ40 Skid Plate

What gauge is the metal you used ?

 

[Mike Shull]

What gauge is the metal you used ?

I used 3/16” plate steel for both. The fuel tank skid is stout though I wish that I had made the transfer case skid from 1/4”. I may weld in some additional reinforcements to this skid along the flat surface to add strength.

 

[Paul]

I thought that some of you would rather see pictures than watching the video. I am very happy with the results and can’t wait to venture back into Utah to test out the new equipment.

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[Paul]

Nice work Mike!

 

[Mike Shull]

Part 1: Stretched Chassis & Custom Suspension

Thanks, Paul!

I added another video that dives deeper into the chassis and suspension. Enjoy.

 

[Paul]

I love your build. Inspiring for me. Thanks.

 

[Blackknight1]

I used 3/16” plate steel for both. The fuel tank skid is stout though I wish that I had made the transfer case skid from 1/4”. I may weld in some additional reinforcements to this skid along the flat surface to add strength.

Wouldn't 1/4" steel pate be too heavy ? I do get that armor is necessary , but won't so much added weight affect anything else ?

 

[Mike Shull]

Wouldn't 1/4" steel pate be too heavy ? I do get that armor is necessary , but won't so much added weight affect anything else ?

The difference in weight between 1/4” and 3/16” plate is about 2.6 lbs per square foot so building the transfer case skid from 1/4” only would have added another 5 lbs. The transfer case skid plate is pretty small.

Normally I would agree that 1/4” is overkill for a skid plate. I’ll have to get this out in the rocks and see how strong it is, or maybe I should put a jack under it and see if I can lift the truck from the skid. Now there is a great idea.