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Got all the nonsense holes plugged in on the driver side, used 1” round tube caps Cleaned off the old mount in preparation for gusseting it again. Using 1/2”-13 welded nutserts

Thanks!! The goal is to really forge ahead and make some serious progress in the coming months

Planning ahead for the rear sway bar. We are going with a custom length Sway A Way Bar should sit where the blue sharpie line is and have room to articulate upwards to max bump Unfortunately about 1/2 of the factory bed mount has to be chopped off since it extends outboard of the frame See...

Got the passenger side coil notch completed today Blasted through the frame…. Welded and DA sanded Sanded and blended out the driver side notch also Fairly minimal intrusion into the frame once it’s all welded back up

That is completely true. The amount of frame mods required to sandwich in a suspension like this is ridiculous. FAR more than I was planning on

Thanks! Slow but friggin’ steady

Cut up some chunks of DOM to make rear frame reliefs. At max droop, the coils were JUST making contact with the outside of the frame Of course there just had to be a nasty old chunk of frame or leaf spring support right where it needed to go 🙄 Relief pieces, they are .120 wall Done...

Couple small things today Mounted the Hole Herse floor switch for the headlight High/Low beams Fully waterproof and tucked up behind the inner fender

Full droop. Quite a bit Ride height. About 1” of up travel before the axle begins to hit the bump. Bumps have 2.5” of travel

Rear bumps are in, what a pain. Apparently it’s a well documented issue that the King bumpstop cans distort when they are welded, which makes it impossible to get the bump in and out of the can. After fighting this for a bit, I had a friend machine up an aluminum slug to help keep the can round

Moving on to finishing out the rear suspension. Need to set the King bumpstops in for good and determine the limit strap length This is full stuff driver with the passenger side coil over fully dropped/extended. Essentially the wheel hub is on the floor Perfect fit!! Blue towel roll is...

Got the whole exhaust mess in. It’s tacked and has support brackets, just needs to come out for final welding LOTS of bends. This piece gets the exhaust up and over the rear frame rail 3rd Borla muffler, right under the bed and just behind the 14B axle. 3 mufflers? Since neither one of us...

Monkeying with the exhaust again. And HAPPY NEW YEAR! 💥 💥 Added quick disconnect flanges to all 3 ends of the cross over pipe Stainless flex joint and Borla muffler… Snaking it through the cross member, this is a full 3” exhaust from the headers back Stainless hangers with...

Moving on to something less tedious than sheet metal work. 1.5” spacers arrived from Wheeladapter.com These are machined from Timken steel and use a 10.9 wheel stud. MUCH stronger than OEM. These were needed to give us a bit more clearance at extreme articulation as the tire is quite close to...

It’s in, not fully welded yet Correctly getting it to line up as best as possible required my wife pushing the hell out of it in several places as I tacked it into place. The Taiwanese steel is also a joy to weld on, just full of impurities :(

Thanks for the encouragement everyone!! Got a bit closer today and managed to finesse the driver cab corner into place! Reinforced the interior of the “B” pillar Made supports for the upper part of the cab corner One example of many regarding how poorly these panels fit. The original 90...

Front panel support… Rear rocker cut down to match interior panel contours “B” pillar cut down to size, fitted and tack welded Fully welded and sanded/blended down at the seams Welded rocker, I’ll add the cab corner tomorrow

Shifting gears a bit… I’ve been putting off the sheet metal and rocker replacement because I dislike body work so much. Time to just get it over with It’s pretty hard to find panels for this vintage FSJ. We had ordered rockers from BJ’s off-road but the fitment was TERRIBLE. None of the...

Oooof, that’s a heavy sucker. The drivetrain can certainly take it but I’m hoping it’s not THAT heavy for off-road stuff

Blasted and nearly ready for paint and reassembly. Flat surfaces got smoothed with a DA No more rust on the inside now So here’s some input shaft comparison. The middle shaft is a new “Fat Shaft” from Off-Road Design. Left shaft is from this case and the right shaft is from a different...