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corax · 05-06-2008, 08:16 PM

I know Total Chaos sells one, but I wanted it flat on the bottom so I could bolt a skid on later (and link to a Budd Built cross member, which is another future mod). I know Sonoran Steel makes one, but it looks like major overkill (and I'm trying to limit how much weight I add). I had one from Front Range Offroad on a previous project, but they don't make them anymore & I didn't like the way it bolted on. I didn't want a weld on truss because I'd like the option of unbolting it to make dropping the front diff easier.

This is what I came up with, design is based on the Front Range truss, but with weld on mounts. Fab time + install was only ~4 hrs using 2" x 1/2" channel and 2" 1/8" flat bar.

installed and painted - everything was assembled & both mounts drilled & bolted with it off the vehicle. I tapped it into place between the lower arm perches & welded up the mounts. that way I know there is no slop in the mounts and everything is a nice tight fit. It's strong enough I can jack up the front of the truck with no visible deflection on the truss

Since I spent so much time on the radiator and fan getting them to fit, a bit of pretection was in order. I built and installed an expanded steel grill to keep the rocks out of my radiator. used 1/4" square rod on the sides to keep it from bending as easily, it's the gloss black bit under the factory grill

Roof rack was swiped off an Isuzu Rodeo, the cross bars were shortened so it would fit between the rear windows. It's mounted with 8 6mm stainless bolts through the shell with brake line cut to length to prevent the walls of the shell from distorting when everything was tightened down. In addition to the factory rubber gasket under the side rails I used just a touch of RTV to prevent and water leaks, so far I've had none.

05-06-2008, 08:16 PM	#4 (permalink)
corax Registered User Join Date: Aug 2007 Location: eastern PA Posts: 631	I know Total Chaos sells one, but I wanted it flat on the bottom so I could bolt a skid on later (and link to a Budd Built cross member, which is another future mod). I know Sonoran Steel makes one, but it looks like major overkill (and I'm trying to limit how much weight I add). I had one from Front Range Offroad on a previous project, but they don't make them anymore & I didn't like the way it bolted on. I didn't want a weld on truss because I'd like the option of unbolting it to make dropping the front diff easier. This is what I came up with, design is based on the Front Range truss, but with weld on mounts. Fab time + install was only ~4 hrs using 2" x 1/2" channel and 2" 1/8" flat bar. installed and painted - everything was assembled & both mounts drilled & bolted with it off the vehicle. I tapped it into place between the lower arm perches & welded up the mounts. that way I know there is no slop in the mounts and everything is a nice tight fit. It's strong enough I can jack up the front of the truck with no visible deflection on the truss Since I spent so much time on the radiator and fan getting them to fit, a bit of pretection was in order. I built and installed an expanded steel grill to keep the rocks out of my radiator. used 1/4" square rod on the sides to keep it from bending as easily, it's the gloss black bit under the factory grill Roof rack was swiped off an Isuzu Rodeo, the cross bars were shortened so it would fit between the rear windows. It's mounted with 8 6mm stainless bolts through the shell with brake line cut to length to prevent the walls of the shell from distorting when everything was tightened down. In addition to the factory rubber gasket under the side rails I used just a touch of RTV to prevent and water leaks, so far I've had none. __________________ -Keith- kb3scj '88 4runner SR5 - 3.0 7MGE eng swap - Marlin HD W56 - 4.56 V6 Thirds - '82 Toyota Celica Supra LSD up front - 33x10.5 BFG KM2's - NWMP Aux Gas Tank - home fab front and rear bumpers - Hannemann fenders - OME Dakar rear springs w/ Bilstein 5150 reservoir shocks Garage Thread "Speed doesn't kill, suddenly becoming stationary does." - Richard Hammond Last edited by corax; 11-27-2008 at 07:14 AM.