Hello Car Domainistas! This page will outline our new project, to be debuted at SEMA in the fall. We affectionately call it "The Dog" yet it's official name is the ICON CJ3B. As our production ICON FJ's are inspired by the original Toyota Land Cruiser, the new model is inspired by the old Willys flat fendered CJ3B. We designed this one in Solid Works (and Catia) from scratch, with a dedicated coil suspension chassis, production Rubicon axle assemblies, Jeep application AX15 five speed and New Process 231 transfer case. Target weight of 2400 lbs, 260 HP. We will build a dozen or so as full turn key vehicles, thus refining the process to allow for clients to purchase it in engbineered component vehicle "kit form", ala the old Popular Mechanics back page ads of the 1960's. A modern take on the classic, CAD designed, simple fun father and son (daughter) project, using simple hand tools (no welding). We will launch with an Ecotec 4 cylinder gasonline engine, yet are developing a pure EV variant with four in wheel hub motors and a driver controlled variable crawl ratio for off road versatility. For now, we are offerring a "beta batch" of ten units, with special high level of content and equipment, all built by hand by the designer, Jonathan Ward. They will be sequence data tagged and price fixe. They will be unique and of the highest quality. We will use this first batch to help us fine tune and perfect the program, so that we may offer a full range of versions from component vehicle sales all they way through to full turn key vehicles in the near future, all at the lowest price point good business practices will allow. We hope to soon offer Kit packages from $15,000-35,000, with eventual turn key production vehicles hoping to start at about $45,000... Stay tuned as we proceed!

So here is our original inspiration, an old CJ3B Willys. I have always been impressed with the clear priorities of the original Willys designs: simplicity, longevity, and utility. We searched high and low to find a virgin CJ3B from whcih to get some key data and detail inspiration.

Then we put together a list of key suippliers and components available to us already, to help us outline what we would need to be responsible to design or update... Based on our experience designing the FJ ICON's, we had clear targets and priorities for the chassis. So oddly enough, that part of the process went pretty quick. Our design team is a five man effort. Here we are, sweaty and all, at our engineering facility in Temecula,CA. I, Jonathan, am on the left. Jeff is missing from this image because he was in the hospital, having just launched his KTM bike into the wrong part of a jump... . He is still sore but back on the team now!

Next step was to call all of the key suppliers, and coordinate the shipping of all "off the shelf" components. Once they all landed, we started to Leggo them all together, to get a feel for the scale and proportions......

Now it was time to get busy on the computer, to design the chassis that worked with our concept layout in Solid Works. We found it to be quite challenging to fit all the modern content into such a small package! Here is Ryan hard at work....

 

Once the rails were designed, it was time to start on the axles. We decided to use new Jeep Rubicon production axles with locking differentials for this platform. We worked with our friends at Dynatrac to aquire the production axles, which we then took apart and modified for our narrower track width, and improved a few details of the design while we were there.

 

So once the axles were modified, it was time to set them up under the rails thast our buddy Art Morrison crafted up for us. Time to check travel and twist.

Looks like a good 8-12" travel <UPDATE- turned out to realize 24.5 inches of overall travel!>, using progressive Eibach coils and Fox Racing Nitrogen charged shocks with remote reservoirs. So once that was approved, with proper scrub/dive/squat rates estimated and Ackerman angle set, time to move forward. We chose 3/4 ton steering compopnents, with .188 suspension arms utilizing heavy duty Johnny joints and US made Teflon lined Heim joints. Frame is crafted in mandrel bent 1.20" wall steel.

So, now we began the process of digitizing the body and all details of the design. Here are some screen shots of the chassis and body in development......

 

 

So by now the platform is coming together quite well, and we started working out the design details such as the gauge panels. roll cage, seating, drivetrain positioning etc... .

Just got back from the engineering office, and got my last look at the (relatively) complete assembly before we tear it apart to finicsh weld everything. We just finished the front bumper design, and I am happy with the results. Puropseful and compact, and it fits the WARN winch like a glove, with the relay box tucked into the front bumper and the hawse fairlead centered through the front bumper face. You like?

Notice that the mount plate is an integral part of the frame now...

Now that we knew the drivetrain angle was committed, it was time to design a nice skid plate. We chose to use existing transmission mount pick up points. CLean and high clearance.

Here are some shots of the chassis with the skd plate removed.

Ended up pulling the single Eibach 250# springs (was like a chiuaua on pogo sticks) in favor of dual/progressive coils. Eibach has been a great company to work with on this project, very helpful and responsive. Here is the final layout (front shown)-

What else.... finished the removable cage shade canpoy. Tired of noisy canvas, so this time it is solid alloy. We will powder coat it ICON Volcanic Black and then laminate it in the cool Chilewich woven vinyl we use in the FJ ICON's.

Last few beauty shots before final assembly.... now we will take it apart for finish coatings and electrical system design! More soon! Please check back in with us periodically, as we quickly proceed with the creation of the IOCN DOG! Next week we should have the assembly completed, and we will tear it down for finish coatings and electrical system design! Let us know your thoughts! Check out page two if you are a specifications junky, and see what is in the recipe!

OK, tore it all apart and sent everything out for powder coating. I hate paint, and ICON uses powder coat finishes on everything, even our body assembly, which is coated in a polyester Teflon hybrid super durable powder developed for ICON by Cardinal. We offer it in seven standard colors. This one is goind to be finished in our Mocha Sand color, with Volcanic black trim.

Here is the content reduced to a bunch of boxes....

Sand it until it is baby butt smooth.....

Axles sanded, etched, primed and painted. Our friends from Stop Tech came by, and set us up with powder coated calipers with improved rotors and pads...

 

Sorted and in line for media blasting.....

OK, all apart now. Had our powder coaters do us a favor and meet us at 6AM, and turn around the chassis and all black small parts 8AM the next mornings. Thanks AJAX! Look how nice...

Spent today (Friday 10/2) assembling the rolling chassis. 7PM- here is where we are now...

This weekend, we hope to plumb the chassis (brakes, clutch and fuel system) in stainless, and be ready for the transmission, clutch flywheel etc to assembly on the engine. Body should be back from powder and Line-X by the end of next week, so next weekend is hustle time on final assembly!

So finally, the chassis is done. Now time for finishing the body. Down to raw metal, etch coat, prime coat, filler coat(s), base color and cured top coat, all powder coating, no paints used at all. Super durable finish, with our signature textured finish (we do it in nine colors) with suspended mica. The powder is developed with Cardinal coatings and Andres Powder Coating...

Got the body back today (Thursday), quickly placed it on the chassis to final check clearances and plan the routes for chassis plumbing (in stainless steel). Then off again and out to Line-X to have the floors (in and under) coated in heat cured poly urea.... Once it comes back tonight (Friday), we will begin final assembly!

Got the main assembly done, now just down to some small details. Got the new front grill panel on and check fit, now it is off at powder coating. Headlights work great, all LED's, super bright and efficient. Some chat rooms seem to hate this grill, but keep in mind the original Willys panel fits right in so as you wish..... but we wanted to distinguish our trucks.

Gauge poanel ready..... I think I will make it larger next time, with room for a few more rocker switches.....

The audio module came out great too. No head unit, just an Ipod to an amp to speakers, nice and simple. All of it fits as one module, under dash!

We designed the art on the tailgate in the original font, now saying "The Dog" (trucks nickname). Here you see the stencil before we apply the next layer of powder coating in black.

OK, Well I am sursprised to say, we are done! With a few weeks to spare! That is quite rare on any SEMA project, especially one CAD engineered, from concept to prototype in 7 months! Rides and hadles quite well. After SEMA, we will work directly with the engineeris at Magnaflow and Eibach on final adjustments to those systems, but for the most part, we are done!

Just had a chance to ramp articulate test it. This little truck twists up great! 24.5 inches travel, as shown above where we max'ed out our ramps! We also corner weighed it and found that we are at 49/51 weight distribution. This will be the heaviest oof models we offer (called New School Design package), weighing in at 3060 pounds. Our Old School version (under construction now) will be about 2850. Thanks to everyone for your input and support! Here are some final shots taken at a few photo shoots we did in different areas of Southern California with a few magazines. We have started selling these already, and have all sorts of plans for the platform. Let's see where the road leads us.....