Start:

Finish:

OK.... here is another one we are working on for SEMA that we can share with you guys. Started out a tired ol'Cruiser with about 500,000 miles on it. We like to recycle, so we decided to make an ICON out of it. This ICON was special ordered by a repeat client and friend of our brand. This time we are doing a long wheelbase FJ43 model ICON, in the New School Design package... in our newest color Black Sand. This one will be a monster with 550HP, Race Suspension package, Sport brake package, our new Recaro heated and vented seats plus a host of other options and a few prototype concepts we have been wanting to try out. So if you are into these sorts of things.... enjoy the ride as we hustle to get it done!

Once we tore it apart to the bare frame, we found some structural rust issues. A year ago we would have worked on fixing it or abandoning the truck altogether. However, we recently finished development of a new replacement chassis design with the guys at Art Morrison, so this seems like a great opportunity for that upgrade!

Here is the new frame...

Here is the new alloy body being placed for a pre-fit check...

Seats in... These seats are cool. The are vented with small fans in the back and bottom, plus heated and power function controls. Recaro makes great stuff. I will get rid of their upholstery though........

We got the dimensions we needed for a custom box and rear seat design, prefit everything, so now time to tear the body apart and send it into the oven for powder coating........ here is is back and still apart...

Here you see the box in raw alloy...

Now we assembled the tub and you see it here getting ready to go into the Polyurea booth for the coating to be applied on the floors and bottom surfaces for insulation and corrosion protection.

By this point the chassis is back from powder and we started reassembling it on Monday (Sept.22).

Coils and springs fit, bump stops and remotes... 

Fuel system and plumbing...

Look a that sexy engine....

Lets take those plastic valve covers off and come up with something nicer...... In the meantime we set ourselves to the task of assembling the engine-transmission and transfer case....

Hang it in the chassis......

Fit some custom power steps as per client request.....

Meanwhile.... our first set of development axles based on the proven Dynatrac Dana based Pro-Rock Dana 60 complimented by StopTech engineered ICON Sport Brakes are nearing completion. We hope to fit them into the chassis this coming Monday, then the rolling chassis will be complete (minus exhaust). We expect the body back tomorrow, so we will start the cabin assembly. The electrician is soldering like mad to be ready in time...... fun fun fun.

Here are some shots of the brake system.... sick stuff. Fronts are 355x32mm (14") slotted and vented Aerorotors with billet aluminum 7075-T6 hats, rears are 328x28mm (13") slotted and vented Aerorotors with billet aluminum 7075-T6 hats. Front calipers are six piston monsters, rear are four piston with a dedicated parking brake. Serious equipment for a serious ride.

We will not run drilled rotors because in a truck application they are no fun once bogged up with mud. These were for prototype test fit only...

Just got the body back from Polyurea coating the underside and floor surfaces last Friday. Spent the weekend assembling the body. Still waiting on the final production axles with brakes from StopTech, should land tomorrow. In the meantime, here are some images of where we stand now. Got the harness done, now routing it. Hope to unite the body with the chassis in a few days! 

Hard to tell, but here is the floor area in the cargo section, from below. Nice and durable coated surface. 

Seats are in, body coming together. Hope to get the body on the frame by the end of the week! 

Got the axles, finished the chassis assembly... look how nice......

Mounted the Hutchinson wheels...... super cool beadlocks......

Last look at the chassis before the body hides all the details. Kind of a sad moment for us builders, as we see the chassis as a work of art without the body. Most of our clients never even peek under the truck to see such exceptional design...

going...... going....... on!

So now the soft top is done, as are the half upper canvas doors.

We got these cool MOZ 20" wheels and Pirelli Scorpions. Not sure if we will run these or the Hutchinson's.

I like how these show off our new brake system but they are a bit wide.

Got the CNC work completed for the valve cover inserts, here they are before we polish and black enamel fill them.

Here is my new removable rear seat prototype. We just prefit it to place the anchors, now it is off to get the upholstery. It is designed like a patio or beach chair, with suspended woven Chilewich vinyl and no foam, so it is portable, versatile and light weight.

Still need to finish the harness and gauges, design and fit the intake...... tons of little details but at least we see the light at the end of the tunnel! 

OK, nearing completion.... . The Pirelli tires were buggin' me. Too street. Reminded me of a 70's skateboard. BF Goodrich saved the day and hooked us up with a set of 37" M/T's. What a difference. 16" of ground clearance at the pumpkin! Surprised they fit, but we cranked the coils up and it worked out great.

Now the AMP Research hideaway steps really come in handy...

Dash all together now, NAV hung,  gauges in...

IPod dock ready, Sat dock ready...

heated and vented  Power seats juiced... .

Micro LED lights hidden everywhere...

Rear dual carrier bumper done and detailed. Note the self-actuating pivot stops. Spindles are built into arms, and sit down into body of bumper with dual bearings and races. Strong but still low profile.  CNC'ed Billet handles

Check out these trick custom pedals we just fit- 

Engine bay almost done. Just hand built the intake, fit the custom covers, hi-line transfer case breather, reservoir for power steering etc.... ARB compressor...

.