Thinking I might start collecting parts (much to the chagrin of the wifey & lack of garage space, but oh well). Wondering which way to go with it...

I know the 1st answer from most will be a D44, but I'd rather stick with Toy if I can. I was figuring the fj80 has a width of 65.5", so I'd be fine with the idea of running some 1" or 2" spacers... This may also coincide with an engine swap (possibly the D4D, maybe something bigger - dunno yet), so some additional weight needs to be considered. I'd prefer to stick with leaf springs, so the buckets would get cut... What about custom tubes & shafts?

Thoughts...
Thoughts...
Thoughts...

looked into diamond axles, not sure if that would be cheaper for a custom setup...

my primary concern when i was figuring which i would do (LT vs. SAS) was shackle location, would shackles towards the back work without having them under the frame?

FJ-80 is in the 63.5" range. If you want to stick with Toy, your best bet is the Diamond, but its pricey. In addition to the housing cost is custom length axle shafts and steering. However, if you do go with a Diamond, I'd have them set it up for the T100/Tundra diff so you have the extra strength and the same diffs front and rear.

The D44 is cheaper than the Diamond setup for a wide axle and it steers tighter.

On Surlynkid's rig we put the shackles up front so we didn't have to worry about trying to mess with the rear frame/shackle location and so that the axle would travel forward when it stuffed into the fender for better firewall clearance. How it works offroad... we may never know. <img src="/forums/images/graemlins/ignore.gif" alt="" /> <img src="/forums/images/graemlins/lol.gif" alt="" />

Ouch! <img src="/forums/images/graemlins/notooth.gif" alt="" />

It's waaayyyy close to the cat under the frame as it is. I don't see how one would go through the frame without relocating the exhaust. Under has worked fine for me for several years now, though, both on and off road. It's not all that purty, but plenty functional.

Would having the shackles in the front potentially cause the sensation of play or slop in the steering? Seems it would have the ability to shift side-to-side without some sort of locating bars... Or is that the brunt your steering now has to take on?

Adam - did you notch your frame or surface-mount a bracket that drops down some? How much lower than the crossmember does it all hang?

I recall seeing some custom axle ads (for Heeps) a few years ago that seemed like an odd & interesting hybrid - sort of an independent-style front drivetrain that had been encased in a solid axle housing & attached tubes. Made the bottom of the diff sit right around the same level as the bottom of the outside mounting flange... Anyone know who I'm talking about?

Happy New Year all! <img src="/forums/images/graemlins/cheers.gif" alt="" />

we cut out my cat, clocked it, and welded it back in place. it freed up the necessary room.

Surface mounted. Which crossmember, the front spring hanger or the transmission? Either way, it's kinda hard for me to visualize, and I'm 5000 miles away from it for a few more days. This might give an idea, but if I can find some SA hubs I'll be under it a while once I get home and can get some hard numbers for ya.