Firewall tub on my 97 limited- pictures and mini write up

[CT135]

Chose to go with a decently aggressive firewall tub. Inspired by pictures I saw on freel good performance on Instagram.
Marked off the areas to cut with a marker and got to cutting with an angle grinder and sawzall.
Got a chunk of cardboard shaped to the hole and cut it out of some 18 gauge sheet.
Beat it into shape and welded it in there.
I used seam sealer on the inside and outside, once that cured I also added some windo weld in the bottom corners of the inside and a few other spots.
Hit the inside and outside with a couple coats of 3M fender liner.
Trimmed the limited flares and trimmed the fender to roughly 1/2” away from where the limited flares clip in.
35’s will be here in about 10 days and I’ll see if I need to do any extra trimming at the bottom of the limited flares.

It was a little uneasy cutting such a large hole but it turned out well. I think it still looks close to factory to the untrained eye, especially when the New paint gets dirty to blend in.

I’ve washed it, and driven about 50 miles in the rain, zero leaks. The seam sealer and window weld combo works great in my opinion.

 

[Joelzy]

Great work, i think i might be getting into this one come summer.


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[spartacus]

Nice work looks good. Have you given any thought if the fronts are going to rub on the frame at full lock. I believe [MENTION=143526]theesotericone[/MENTION] actually notched his frame for that.

 

[CT135]

It’s definitely a 2 person job, someone to make sure all wires are out of the way when cutting and for fire patrol when welding in the new plate. Maybe it’s easier with gas but I don’t have one so it was a slow process. I did passenger side one day and driver side another. Took about 12 hours in total but I’m kinda slow when I work on stuff.

Great work, i think i might be getting into this one come summer.


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[CT135]

I’ll be running 17x8.5 wheels with 0 offset and 1.25” spacers. I’m 90% sure that from what I’ve read that setup won’t rub but if it does I’ll have to look into notching the frame. Thanks for the heads up!

Nice work looks good. Have you given any thought if the fronts are going to rub on the frame at full lock. I believe [MENTION=143526]theesotericone[/MENTION] actually notched his frame for that.

 

[RomanSchnobrich]

Great little write up! Lots of important information here and helpful tips, thanks man!

 

[theesotericone]

Nice work looks good. Have you given any thought if the fronts are going to rub on the frame at full lock. I believe [MENTION=143526]theesotericone[/MENTION] actually notched his frame for that.

I never notched for 35's. I will probably have to notch for 38's though.

 

[CT135]

I never notched for 35's. I will probably have to notch for 38's though.

38’s?? I’m assuming a sas is involved?

 

[theesotericone]

38’s?? I’m assuming a sas is involved?

No SAS. Frame notch and engine cage. Lot's of sheet metal work on the rear. Push the rear axle back 1" via upper and lower links. I'll also have to throw a 1" body lift on.

 

[Dezert4Runner]

I love the graphic art on the sheet metal

 

[T4topher]

Just got 315/70/17’s a few days ago. All I’ve done so far is flatten out the pinch weld and moved my LCA cam tabs so that it pushes the wheels as far forward as possible. Don’t rub at all at ride height lol.. Either this weekend or next I’ll be cutting into the firewall.

 

[wrench.n.wheel]

I wish I did this originally, but I did it the lazy way and went to it with a hammer. Its not nearly as clean, but you do not have to weld, just have to be careful when hitting with the hammer to not punch a hole through it.

Great work!

 

[CT135]

I wish I did this originally, but I did it the lazy way and went to it with a hammer. Its not nearly as clean, but you do not have to weld, just have to be careful when hitting with the hammer to not punch a hole through it.

Great work!

Did you have to trim the fenders at all to fit at stuff? I have mine trimmed but the flare is still hanging down. I’ll have to see if my tires tuck inside or if I need to do some more trimming. I already cut the fender up almost to the clip holes.

 

[wrench.n.wheel]

Did you have to trim the fenders at all to fit at stuff? I have mine trimmed but the flare is still hanging down. I’ll have to see if my tires tuck inside or if I need to do some more trimming. I already cut the fender up almost to the clip holes.

I have a 1" body lift, i only had to trim small section at the bottom below the SR5 fender flare.

i still rub a little on the fender flare in the rear.

 

[T4topher]

Did you have to trim the fenders at all to fit at stuff? I have mine trimmed but the flare is still hanging down. I’ll have to see if my tires tuck inside or if I need to do some more trimming. I already cut the fender up almost to the clip holes.

How big of a piece of 18 gauge did you get for both pieces?

 

[CT135]

How big of a piece of 18 gauge did you get for both pieces?

2 sheets of 16x24. Had plenty of extra space in cause I messed up my original cut and needed some to patch. Luckily I kept it all in one chunk.

 

[T4topher]

2 sheets of 16x24. Had plenty of extra space in cause I messed up my original cut and needed some to patch. Luckily I kept it all in one chunk.

Finally just finished. How did you mount the modules that were attached to the firewall itself? I got all the wiring hooked back up except those 2 modules, was thinking about just using some zip ties but wanted to see if there was a better solution?

 

[CT135]

Finally just finished. How did you mount the modules that were attached to the firewall itself? I got all the wiring hooked back up except those 2 modules, was thinking about just using some zip ties but wanted to see if there was a better solution?

Mine were still able to clip back on. It took a generous smack but they stayed when I hit them. The bottom isn't hooked but the top was able to latch. It doesn't rattle off road or anything so I'm leaving it as is. Zip ties would be an easy fix though if yours isn't latching.

 

[T4topher]

Mine were still able to clip back on. It took a generous smack but they stayed when I hit them. The bottom isn't hooked but the top was able to latch. It doesn't rattle off road or anything so I'm leaving it as is. Zip ties would be an easy fix though if yours isn't latching.

All the clips and everything still pops back into their original locations, but on the driver side there is the 4wd module (black box) which had a 10mm bolt attaching it to the firewall. That attachment is no longer there after cutting.. I think passenger side has something similar as well.

 

[CT135]

All the clips and everything still pops back into their original locations, but on the driver side there is the 4wd module (black box) which had a 10mm bolt attaching it to the firewall. That attachment is no longer there after cutting.. I think passenger side has something similar as well.

Oh ok I know what you’re talking about. Passenger one I just shoved in and closed it up without bolting it in. Driver side there was one available spot that I bolted the 4WD module in. It’s sitting at a weird sideways angle but secure.
I’d say zip tire most of it together and it’ll all stay tight and you’ll be good to go. Make sure you test 4WD and locker. I was nervous after all of that cutting and pulling wires around.