Ok guys so here is the deal, I am planning on turning my 5th gen ltd into an expedition style rig. I went to total chaos fabrication a while back to get some R and D done and to see if they can build a long travel kit for the 5th gen. The existing FJ long travel kit does fit the new 4runner except for the wheel clearance in the fender which will force me to get fiberglass done. I currently have my truck in the hands of Jason Demello who is building the protype front bumper and sliders. The plan is to drop it off with a fiberglass company to build a custom fender set for the vehicle. Once that is done and painted, the vehicle will be in the hands of TC for the suspension mods. As I have been waiting patiently for the bumper to be completed I have been going back and forth with the thought of modifying the fenders although that is the only way I can get a long travel setup to work. If cost was not a concern what would you guys do?

it doesn't sound like cost is a concern at all!!

Most of the Tacoma guys who go LT get fiberglass. Sometimes it looks like a$$. Like chipmunk cheeks after you get your wisdom teeth pulled. But if you're going LT, you're doing it for fun, not looks. I say go all out and enjoy. Just make sure the fiberglass is painted to match and doesn't look out of place. I'll try to find a pic of a Taco to explain what I mean.

But i'm definitely excited to see it done!

Like this VVV the fender looks good, but where it attaches to the lower bumper looks like a$$

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Thanks for the example, well my issue is going to be with the fender matching up with the new demello bumper and the plastic that has been trimed from the old bumper right above it. But yeah your right this is going to be set up for outdoor adventures but it would be cool to have that bada$$ factor when driving it around town. I'm pretty much already commited to the LT setup and will be dropping by glassworks this sa****ay and see what they can do. It may be ugly but I'll be able to jump it. haha

Very nice!!!

Keep us posted for sure. I thought about the LT kit too, but then hit the fender hurdle and decided not to proceed.

Really cool you are going to move forward. That thing will be sick when its all said and done!

Also there are a ton of pics on their website. Maybe get some ideas and pics to show the glass guys. I think that blue FJ is just incredible!!!!

Congrats!!!
So that's your Limited in Demello's! Lucky you, as Jason will have that thing lookin bada$$ by the time he gets done with it.Make sure and drop the hint about how nice a new rear bumper with a swingout tire carrier would look and sell!!lol

They might be able cut the lip of the fenders ,then fab and put on some bigger flares rather then whole new fenders. Because the 5th front fenders have some intricate lines and creases and are actually a work of art in my eyes!

Thanks Bflan, yeah I will check it out... You guys are making it easier for me to go through with this. I have been keeping this under wraps for a while specially since what good is a thread without pics but really wanted to get some opinions from you guys. I will be posting pics thoughout the tranformation. The Demello thread already has pics of the front end, everything else is still stock but wont be shortly.

Yes it is, thanks Harper7. BTW the guys at Total chaos told me about someone out in Texas that is running their UC's. They then showed me the pic of your truck and I was like I know that guy, he's in the forum I hang out at... And about that tire carrier, will do. I'll just tell him "well the truck is already here might as well finish up the rear end".. haha

I was thinking the same thing about the fender. They do have some distinct lines that will be tricky to reproduce. I was hoping that bushwacker would come up with some cutouts for the 5th gen. But yes I will see if I can have them cut out and do some custom flares.

Kudos to you, Dlak! Very excited to see how it turns out. I know what it is like to go without my 4R after tasting of the goods... However, I second Harper's motion on the rear bumper I have pondered some time about the feasibility of placing the spare on the roof rack, and I just don't think it is ideal at all. Too heavy once you up-size and go for something more aggressive. I would like to get a wider rim (9", the ATX Artillery's are calling my name) and doubt that it would fit acceptably under the back.

Anyhow, thanks for your bravery in facing the front fender chop. I'm sure you won't be disappointed that you did, Demello seems like a great operation.

i may have to stop by Demello's shop and check out your truck.....oh, and inquire about them sliders too (for myself of course ). corona is just a little east of where i live.

i'm sure i can speak for many of us by saying thanks for allowing him to work on your truck, without your courage and sacrifice we wouldn't be drooling over what he's making for our 5th gens. can't wait to see how your truck turns out! keep us posted!

Thank you, and yes after reading up on all the mods you guys have been doing to your trucks I couldnt pass up chance to do something to help out the T4R community. I know it is not the first bumper and slider out there but atleast we are starting to get various choices on styles and design.

Drop by the place and check out the work, let me know what it looks like in person.