The post FJ Cruiser Overlanding – Off Grid in Big Bear appeared first on Forest2Sea Overlanding Adventures.

In between Part 3 and Part 4 of our FJ Cruiser overlanding build-out, CrtrGrl and I did a trial run of our new roof rack and roof top tent. We wanted to try out sleeping in the tent and also see how the FJ Cruiser (Greyjoy) drove with the new weight on the roof. We hadn’t yet installed the camp kitchen that was built in Part 4, but we had our ARB fridge in the back.

Overlanding Trial Run

Our plan was to do a couple of nights of dispersed camping out in the Anza-Borrego Desert State Park. Anza-Borrego is only a couple of hours away from home, and has perfect temps in the beginning of spring. There are a lot of options for dispersed camping and we knew we’d be able to find some peace and solitude.

The only things we needed to bring were food, water and camera gear. Oh and our little dog Indi. 🙂

Adventure Video

Check out the really cool video that CrtrGrl made for for our trial run:

American White Pelicans

On our way to the desert, we stopped at Lake Henshaw to check out a flock of American white pelicans. Apparently, 2018 was the first time they were seen at Lake Henshaw. They are showing up in more new locations in San Diego County due to declining fish in the environmental disaster that is the Salton Sea, where they historically spend winter.

We watched them resting in the lake and flying in formation in the mountain air currents. Pelicans are one of my favorite birds, with so much personality, and the American white pelicans are beautiful! With their large wingspans and striking white and black feathers, they definitely stood out in that landscape.

Camp

After communing with the white pelicans, CrtrGrl and I found a secluded, dispersed camping spot in a canyon in Anza-Borrego State Park. We picked a spot next to a large tree, which provided some shade and privacy. A few trucks passed by during the middle of the day, but after that, we had the place to ourselves.

We set up camp by opening up our roof top tent and zipping in the full annex. We also opened up the rear awning for shade. A few white puffy clouds passed by in the light breeze as CrtrGrl prepared salad and sandwiches with plant-based sausage, sauerkraut, peppers and avocado. As we watched the sun set and the full moon rose, I got out my camera to do some night photography.

We slept well in the roof top tent, with our small dog Indi in between us. The Tepui mattress was just enough padding and our 2-person sleeping bag kept us plenty warm. In the beginning, we were nervous about the part of the tent that is held up by the ladder, but after going up and down a few times, we found it to be sturdy.

Winds

The next morning, we took a walk and explored our surroundings. The canyon branched out into small alcoves that ended in steep walls. During the rainy season, our camp site could be underwater during flash flooding. We were awed by the stark beauty of the desert and the creatures that can survive in those harsh conditions.

As the sun came up, so did the winds. We hiked up onto a small ridge above our campsite and enjoyed a view across the desert floor, as the wind threatened to push us off. When we got back to our campsite, the wind ripped out one of the stakes holding the rear awning in place and flipped it up and over the FJ. We learned that stakes don’t work well in the sand, at least not when it’s windy. The awning ended up with a bent support pole. Fortunately, ARB sells them individually and they’re pretty cheap to replace. Now we carry empty burlap sandbags to hold the tent and awning in place when it’s sandy.

Moving On

With the winds making things less than comfortable in our little desert oasis, we decided to pack up camp and look for another place to stay. Folding up the roof top tent has a little bit of a learning curve, but does get easier with practice. We found that the annex wasn’t quite worth the effort, at least in fair weather and without the need for additional private space.

CrtrGrl and I headed west and up the mountain to check out Lake Cuyamaca. The cloud cover increased, as the temperature dropped. When we arrived after lunch, it was about 40F and the winds were even stronger. Knowing that it was going to get below freezing and might even snow, we decided we weren’t prepared for those conditions and decided to continue home.

After one night camping out in our FJ Cruiser taught us a few important lessons and helped shape the design of our camp kitchen. It was a good stepping stone as we built out the rest of our design. On our next outing, we had the full setup complete and were ready to test it all out before our long road trip.

The post FJ Cruiser Overlanding – Trial Run in Anza-Borrego appeared first on Forest2Sea Overlanding Adventures.

Now that the roof top tent is installed and we’ve built a camp kitchen, next up in CrtrGrl and my FJ Cruiser overland build-out is installing some accessories. Our goal is to make camping and exploration easier and more comfortable, by spending less time setting up camp and having more time for nature and photography. We want to make sure we can get ourselves out of any situation, carry extra gas securely, and have extra water.

Our Choices

• Power
  • Goal Zero Yeti 400 Lithium Portable Power Generator
  • Goal Zero Boulder 100 Briefcase Solar Panel & 15 ft extension cable
• Recovery Gear
  • Hi-Lift XT485 48″ Jack with JakJaw slider tube adapter
  • MaxTrax MKII (black)
  • 20′ Tow Strap & Shackle Hitch Receiver by Rhino USA
• Miscellaneous
  • Rain/Sun Protection – 1250 mm wide (4′) Awning from ARB
  • Fuel – 20L (5 gallon) Red Jerry Cans by Wavian with Front Runner mount
  • Water – 45L Water Tank with hose and faucet by Front Runner
  • Spare Wheel Step Ladder by Front Runner
  • Trash Bag – Surplus USMC FILBE Main Pack Large Rucksac

Systems Engineering / Requirements Analysis

As a quick reminder, here’s the list of features we wanted for our build out. The camp kitchen and accessories meets the following requirements (in blue italic):  

• Easy to setup and take down
• Protection from the sun, wind and rain
• A camp kitchen
• Plenty of extra gas
• Plenty of extra water
• A comfy bed
• Modular
• Shower setup
• Storage
• Off-grid power
• Socially/eco-responsible products
• Durable
• Hot Tub*
• Butler*

_{*Hmm, maybe we’re asking for too much.}

Check out the really cool video that CrtrGrl made for Part 5 – Accessories:

Power

We wanted renewable energy for powering the fridge and charging any other electronics, like lights, cameras and smartphones. A Goal Zero Yeti 400 Lithium battery pack, which can hold 40 amp hours of electricity, fit our needs. It’s setup to charge while driving and because the ARB 50 qt fridge is very efficient and runs on DC power, it’s sufficient most of the time.

If we’re parked in one location for more than a couple of days, we need solar panels to keep the battery charged. We went with the compact Goal Zero Boulder 100 briefcase solar panels. We could have opted for cheaper components, but Goal Zero was founded on lifting up people with less, and we want to support that.

Recovery Gear

For recovery gear, we went with the tried and true 4′ Hi-Lift Jack and added a JakJaw slider tube adapter, since our FJ has rock sliders. It’s the most logical place to jack up the FJ in case of getting stuck or needing to swap out the spare tire. We ran out of mount space on the roof rack, so this goes in the space behind the driver and passenger seat. It’s only in case of emergency, so we don’t plan to use it often.

We purchased a pair of MaxTrax MKII vehicle extraction and recovery devices. In mud or sand, these are the best way to self-recover without a winch or another vehicle. We mounted these on the rear spare tire using a pair of Rok Straps and a cable lock.

Finally, we purchased a 20′ tow strap and shackle hitch receiver by Rhino USA, in case we need to be pulled out or pull someone else out of a sticky situation. These were a pretty low cost insurance option.

Gas and Water

Since the FJ’s gas tank can only hold 19 gallons and they get about 18 mpg on average, we need to be able to carry more fuel. The use case we’re familiar with is Death Valley National Park, which only has one main gas station at Stovepipe Wells and the furthest reaches of the park (Eureka Dunes, the Racetrack) are a stretch on one tank of gas. If you go back to Part 1, you can see a photo of our FJ in Death Valley with two plastic 5 gallon gas containers strapped to the roof. We purchased two 5 gallon Waivian red jerry cans and a Front Runner mount for the roof rack. They are secure, lockable and don’t slide around like our previous solution.

Also in the theme of Death Valley, we wanted a roof mounted water tank. We went with the Front Runner 45L (~12 gallons) water tank and faucet. This allows us to carry extra water outside of the cabin and with a 6′ hose attached, it’s gravity fed and reaches down to the ground for washing dishes and hands perfectly. With a plastic wash tub below it, it’s the perfect camp sink.

Miscellaneous Gear

For access to the roof, especially when setting up the roof top tent, we needed a convenient ladder mechanism. We investigated ladders that attach to the roof rack, but most of them block the rear window from opening. That’s an important feature to us, especially with the way the air dynamics work with the FJ windows – cracking the rear window means you’re not getting blown out in the face while driving. Front Runner had the perfect solution with a lightweight step system that straps onto the spare tire. With the rear door closed, it’s sturdy enough to handle my weight climbing up to the roof.

Trasharoos are the standard for keeping smelly trash outside the vehicle. But instead we opted for purchasing a surplus used USMC FILBE rucksack for less money. They’re virtually indestructible and can hold a similarly large trash bag. We mounted ours on the side of the rear spare tire with the MaxTrax so that we can still use the backup camera in the center of the spare tire.

What’s Next?

And the adventure begins…

The post FJ Cruiser Overland Build Part 5 – Accessories appeared first on Forest2Sea Overlanding Adventures.

Now that the roof top tent is installed, next up in CrtrGrl and my FJ Cruiser overland build-out is a custom camp kitchen. Our goal is to make camping and exploration easier and more comfortable, by spending less time setting up camp and having more time for nature and photography. We want to make sure we have a quick and easy to use camp kitchen.

Our Choices

• Camp Kitchen
  • Cabinet – Custom built by us using 1/4″ and 3/4″ bamboo plywood from Cali Bamboo
  • 50 qt Fridge from ARB
  • 2 x Burner Propane Stove
  • Heavy Duty Locking Sliders for the fridge tray, stove tray and prep surface
  • Self Closing Sliders for the two drawers

Build Video

Check out the really cool video that CrtrGrl made for Part 4 – Camp Kitchen:

Systems Engineering / Requirements Analysis

As a quick reminder, here’s the list of features we wanted for our build out. The camp kitchen and accessories meets the following requirements (in blue italic):  

• Easy to setup and take down
• Protection from the sun, wind and rain
• A camp kitchen
• Plenty of extra gas
• Plenty of extra water
• A comfy bed
• Modular
• Shower setup
• Storage
• Off-grid power
• Socially/eco-responsible products
• Durable
• Hot Tub*
• Butler*

_{*Hmm, maybe we’re asking for too much.}

Design

For our camp kitchen, we wanted a way to prep and cook out of the back of the FJ without having to unload or set up tables. We were inspired by Overland Life’s DIY drawer system and decided to build our own. A fridge, stove and prep area are the heart of the kitchen, so we focused on those. Click on the photos below to see larger versions with captions or mouse over them.

We wanted to build it using sustainable material, so first we looked into reclaimed wood. Unfortunately, there wasn’t really a good option, like left-over plywood. So instead, we opted for new bamboo plywood. It’s pricier than regular plywood, but also stronger and sustainably harvested. We ordered two 4’x8′ sheets – 1/4″ for the cabinet top, bottom and drawer bottoms and 3/4″ for the vertical pieces. Cali Bamboo delivered them.

Our requirements included using the AC plug to charge the fridge while driving and full use of the back seats, up or down. We wanted the back window clear when we’re not fully loaded and planned to use the top of the cabinet for storage when loaded. We took careful measurements of the back of the FJ, noting the minimum widths. Some of the gotchas to be aware of are the sloped back seat, the slant and bulge on the inside of the back door and the four cargo area tie down points. I’ll just say that we probably didn’t leave enough margin in those measurements. At the end, it just barely fit.

Family Project

My dad came to the rescue once again helping CrtrGrl and I build the cabinetry. He has all of the tools required and has experience with wood-working. We spent four days working on it with him and it was great father-son time. The whole family got involved and helped at different points.

The metal trays for the fridge and stove were welded by my brother-in-law, Jason, after purchasing raw metal sheets. One thing we would change about our cabinet is to go with thinner metal sheets for the trays. The 3/16″ metal we have is way overbuilt for holding a fridge and stove and adds a lot of weight. We cut out some of the unneeded metal, but it’s still built for a tank.

Putting It Together

My dad came up with a cut sheet that maximized the use of the 4’x8′ sheets to ensure we had enough wood. The plan was to build all of the vertical components with the trays and sliders and then cut and install the top and bottom last, after we had the exact measurements.

First, we cut the large vertical pieces. Next, we attached the sliders and metal trays to those pieces, which formalized the exact width of the cabinet. We then took measurements and cut the pieces for the drawers, cabinet top and bottom. Once the drawers were attached, top and bottom (‘glued and screwed’, as my dad put it), we added movable partitions to the two drawers.

We tried to lighten the cabinet a little by drilling out circular holes in one side, but the payoff for the effort wasn’t worth it, so we stopped at 4 holes. When it was all put together, lifting and installing the finished cabinet was a team effort, requiring all of us.

Appliances

A 50 quart fridge holds a surprising amount of food and is more than enough to last a week or more in the wilderness. The ARB 50 qt fridge can run off either DC or AC power. We purchased heavy duty locking sliders that are rated at 450 lb each to hold both the fridge and stove trays. They’re more than strong enough to hold a fully loaded fridge and lock in and out, which is great when you’re parked on a slope.

Our stove fits in the second slider tray, under the cutting board. We have a 2-burner propane stove. When it’s time to use it, we just slide out the cutting board, then pull out the stove beyond that. We store the propane bottles in one of the drawers and have a long hose to attach to the stove. Under the stove tray, we have room for a folding table that we use as extra food prep space and as a table to eat at.

What’s Next?

Up next, we’ll add some accessories to our FJ Cruiser before taking it out on it’s first test run.

The post FJ Cruiser Overland Build Part 4 – Camp Kitchen appeared first on Forest2Sea Overlanding Adventures.

Now that the roof rack is installed, next up in CrtrGrl and my FJ Cruiser overland build-out is installing a roof top tent. Our goal is to make camping and exploration easier and more comfortable, by spending less time setting up camp and having more time for nature and photography. Finding a flat spot, setting up and taking down a tent, inflating sleeping pads, un-stuffing sleeping bags and then stuffing them back into stuff sacks. That’s not in our future, unless we’re backpacking.

[See image gallery at overlandingadventures.forest2sea.com]

Picking a Tent

Why did we buy a roof top tent? What features were we looking for? Let’s get into the details.

We want to be able to off-road, so a normal travel-trailer wouldn’t meet our needs. An expedition trailer with a tent would meet our needs, but would make driving a bit more complex by adding a third axle. Keeping it all together on our FJ, named Greyjoy, seemed like the most flexible option that would make driving easier.

Size – we wanted at least a 3 person tent so we’d have a little bit of extra room. Or in real world tent sizing, so we wouldn’t be bumping shoulders all night long.

Weather – 4 season – since we wanted to be able to use it year round, where ever we travel. It needed to be able to hand strong wind, rain and even snow.

Our Bed is Already Made – We wanted to be able to leave our mattress, sleeping bag(s) and pillows in the tent, so they wouldn’t take up space inside the FJ while traveling. Quick setup and take down time was a plus.

Extra Space – We wanted an annex below the roof top tent in order to have some extra sheltered space, where we could get into the FJ during rough weather. We also wanted the possibility of using the annex for a privy.

A hard top tent would very likely improve aerodynamics and gas mileage while driving, but the cost put them out of our budget.

Our Choice

Our choice came down to the ARB Series III and the Tepui Autana Ruggedized SKY – now called the Tepui Ruggedized Series Autana 3. Both offer an annex and have a similar design. Both have an overhead cover to protect you from rain while climbing the ladder into the tent. The Tepui is ruggedized, so the material is thicker, more insulating and hopefully longer lasting. A consequence of the thicker materials is that the Tepui weighs a bit more – 195 lbs vs 154 lbs for the ARB. And the final consideration was color. We’re not usually that big on vanity styling, but the Tepui roof top tent comes in a ‘Haze Gray’ color that goes really well with our 2013 Trail Teams FJ Cruiser. We decided to get the Tepui, even though it’s a bit more expensive than the ARB.

Tepui is making the effort to minimize their environmental impact. This impressive small company has a new Upcycle program, where they make ‘new’ backpacks or duffel bags from re-purposed tent covers. In addition, REI inspects Tepui’s manufacturing to ensure it meets their standards. Tepui is also working to offset carbon for Tepuifest 2018 by planting trees in State Parks.

Timing was fortunate, since we were ready to buy when Tepui and Front Runner had their Black Friday sales. We were able to get 15% off the roof top tent and 10% off the roof rack. Tepui does offer a standard 10% off combo when you buy them together, so the sale just saved us 5% extra on the tent. We had it shipped directly to my parent’s house, since they’d be helping us install it.

Systems Engineering / Requirements Analysis

Check out the really cool video that CrtrGrl made for Part 3 – the Roof Top Tent Install:

Unboxing

What came with the tent? The tent comes boxed up and zipped up, with all accessories folded neatly inside the tent.

• Roof Top Tent
• Annex & Annex floor
• Rain fly
• Roof Top Tent cover
• Extendable ladder
• 2.5″ thick mattress
• Bendy poles for window covers

Orientation

First, we took the Tepui roof top tent out of the box and opened it up on the ground. We removed all of the accessories listed above. My dad and I then figured out how the rails needed to attached to the bottom of the tent in order to mount to the Front Runner roof rack in the orientation we wanted. The options are:

1. Open out over the driver side door.
2. Covering the passenger side door (which in hindsight would have been better, for reasons I’ll get into below). 
3. Flipping open to the rear, over the tail of the FJ.

[See image gallery at overlandingadventures.forest2sea.com] We knew we didn’t want the roof top tent to open over the rear of the FJ because we had plans for that space. Option 3 is good if you want to be able to park in tight spaces and still be able to open the tent. CrtrGrl and I wanted Option 1 with the tent opening out over the driver side door so that it would provide shelter for getting into and out of the truck. With the tent mounted all the way to the front of the roof rack using the Front Runner 8″ roof rack extension, the annex fits perfectly such that you can open both the driver door and the rear passenger door while inside the annex. This configuration was inspired by the Gills Expedition Channel and their FJ setup.

In hindsight, we should have gone with Option 2. With the tent over the passenger side, we could park the FJ such that the wind hits the driver side. The tent annex would be protected by the FJ and the trunk area would be protected by the rear door. Another very minor annoyance with Option 1 is that you have to walk around the rear door when it’s open to get to the trunk.

Prepping the Roof Top Tent

After mounting the rails on the bottom of the roof top tent, we attached the telescoping ladder. It took a little bit of elbow grease to get it to fit between the mount brackets, but other than that it was pretty easy.

With the roof top tent, we also ordered the security nut system by Tepui and the medium mount kit by Front Runner. We opted for the medium tent mount kit instead of the tall one in order to keep the tent lower to the roof, even though the Front Runner rep recommended the tall ones. The shorter mounts made bolting it down more challenging. We weren’t able to use the security nut system, as there wasn’t sufficient room to install it. 

[See image gallery at overlandingadventures.forest2sea.com]

Getting the Tent On the Roof

Getting the roof top tent up onto the roof was a challenge. At ~195 pounds, it was too heavy and awkward for two people to lift. Step 1 was to get the tent into the back of my dad’s truck. Four of us had an easy time lifting it. That got it up to waist height. Next, we thought we’d use two ramps that my parents use to drive their ATV into the back of their truck. Watch the YouTube video above to see how that went.

Plan B for getting the tent up on the roof of our FJ Cruiser was to park my dad’s truck close to it and do a team lift. I climbed up onto the roof of the FJ, while the rest of the family was in the back of the pickup. My son, Christian, joined us for the lift. Five was probably overkill, but it sure made it easier! With five of us, we were easily able to lift the root top tent and slide it onto the roof of the FJ. I helped guide it onto the roof rack, where the medium tent mounts were loosely attached.

[See image gallery at overlandingadventures.forest2sea.com] Once the tent was on the roof, we prepared to bolt it down. First, we centered it side to side in the tent mounts and tightened them down. Then, we pushed the tent forward on the tent bottom rails so it lined up with the front doors. Last, we attached nuts to the bolts and proceeded to bolt it down on all four mount points.

[See image gallery at overlandingadventures.forest2sea.com]

Trying Out the Roof Top Tent

Once we had the roof top tent secured, we opened it up. There’s definitely a small learning curve to opening it up and we’ve gotten better at it since. Step 1 is to undo the pair of cover straps. Step 2, we unzipped the cover. I attached a Front Runner Stratchit to the zipper so we could reach it all the way around the vehicle. That has continued to be helpful the more we’ve used it. For Step 3, I climbed up on the roof, pulled the cover off and undid the four Velcro straps, two in the front and two towards the back. Then I unstrapped the ladder and extended it.

From there, I climbed down off the roof and used the ladder to flip the folded tent open. While flipping the tent open, make sure there is no fabric in the joint that forms the tent floor. The floor should be a flat line, from the half that’s attached to the roof to the half that’s hanging out in mid-air. Finally, adjusting the telescoping ladder to just the right height is a challenge. I’m still not sure if there’s a trick to it, so I usually resort to trial and error. Because the ladder provides support for half of the tent, you’ll want to make sure it’s adjusted so that the tent bottom rests firmly on the ladder, with no bouncing up and down. Also, the angle of the ladder affects how easy it is to climb up, and more importantly, down. The very first time climbing in, CrtrGrl and I were a little nervous putting our weight on the half of the tent hanging off the roof, but it’s really quite secure.

It was towards the end of the day, so all that we did was climb up into the tent to see what it felt like up on the roof. We didn’t try out the windows, rain cover or annex, we’ll save those for next time. 

[See image gallery at overlandingadventures.forest2sea.com]

What’s Next?

In Part 4, we’ll build a custom camp kitchen into the back of our FJ Cruiser.

The post FJ Cruiser Overland Build Part 3 – Roof Top Tent appeared first on Forest2Sea Overlanding Adventures.

CrtrGrl and I have enjoyed tent camping and backpacking and we want to spend more time outdoors than we currently do. We want to make camping and exploration easier and more comfortable, by spending less time setting up camp and having more time for nature and photography. A base-camp, from which we can do day hikes or backpacking, would provide comfort and ease-of-use. It has to be something we can live in for weeks at a time and that supports our lifestyle.

In FJ Cruiser Overland Build Part 1, I shared what CrtrGrl and I were looking for in transforming our FJ Cruiser into an overland vehicle. We figured out a set of desirements that our upgrade should provide. We removed the stock roof rack, installed the side rails of our new roof rack and prepped the rack itself. In this part, we finish the roof rack install and bolt on a couple of accessory mounts.

Systems Engineering / Requirements Analysis

Check out the really cool video that CrtrGrl made for Part 2:

No more junk in the trunk!

A new roof rack is integral to making room inside our FJ Cruiser. It allows us to organize our gear better. We can move stuff to the outside, out of the way.  Because of this, it was the first thing we purchased and installed. We picked the Front Runner Slimline II Roof Rack because it is low profile, modular and sturdy. Front Runner sells a ton of accessories for mounting everything you could possibly want to attach to your roof. We wanted an integrated solution rather than relying on generic mounts that may or may not be secure or fit properly.

Prepping the Roof Rack

With the roof rack still on the ground, my dad and I spent some time trying to get the corner pieces to fit. After the roof rails were installed the previous week, my dad filed down one of the corner pieces to make it a little smaller. We used a rubber mallet to try to square the roof rack – but uh oh, it still didn’t fit. We decided it wasn’t a deal-breaker at that point in time and that we would wait until the roof rack was bolted onto the rails to figure out how to make it fit.

After temporarily giving up on the corner pieces, we tightened down the cross beams. They’re the core of the roof rack and provide a lot of its strength. The heaviest items will be mounted to them.

Next, we installed the wind screen (or bug collector), with the rack bottom side up. The screen sits directly underneath the front facing end of the roof rack and keeps some of the air flow from going between the roof rack and the FJ’s roof. The wind screen helps with aerodynamics and reduces some of the wind noise.

Flipping the roof rack before installation

Finally, we set the mounting bolts into the roof rack cross beams. The roof rack doesn’t mount onto the rails along the outside edge of the rack. The cross beams actually bolt directly into the side rails. When you flip the roof rack over to install, it needs to be end-over-end so that the mounting bolts don’t all slide across to one side.

Roof Rack Install or How Many McGee’s Does It Take?

Four of us (CrtrGrl, both of my parents and myself) lifted the rack up on to the roof of Greyjoy. Extra hands definitely made it easier, even though it’s not that heavy! Step ladders on each side of the FJ also made the job easier.

The next challenge was getting the bolts to line up with the rail mount points. Because the mounting bolts were able to slide along the cross beams, it was a bit of a puzzle to get all of the mount points lined up with the bolts. Watch those fingers when it drops down into the holes! Once the bolts were in the holes, we had to take measurements to make sure the rack was evenly centered on both sides. After that, we tightened the nuts that secure the rack to the side rails.

[See image gallery at overlandingadventures.forest2sea.com]

Roof Rack Accessories

Before installing the four corner pieces, you have to think through what accessories you want to mount on the side rails. For most mounts, you’ll need a locking nut in the top groove of the side rail. Some parts will prevent you from sliding the nut along the rail to the position you want to mount it, like the expedition rails. So planning ahead can pay off in less unbolting/re-bolting to get them where you need them. Ahead of time, I actually drew a cartoon map of what was going to mount where.

With the roof rack bolted down to the side rails, it was time to install some accessory mounts. We opted to put the Front Runner Axe Mount and Shovel Mount on each side of the roof back, near the back. Both were relatively easy to mount. However, unless you already have the shovel and axe you plan to use, you may have to guess and then adjust later like we did. The most important thing is to figure out where the mount should go relative to other components mounted on the roof rack.

[See image gallery at overlandingadventures.forest2sea.com]

Challenge with the Front Runner Roof Rack

We ran into one main challenge with the Front Runner Slimline II Roof Rack. In our last blog, we had trouble getting the four corners to fit together properly when it was on the ground. My dad filed down one of the corners to make it smaller. This got it close, but it still didn’t quite fit.

Once we mounted the rack on the side rails, we still couldn’t get the bolt into the hole on all four corners. I don’t know if this is a common problem or not. My dad got out his Dremel and filed down the same corner some more. By the time it fit, the edges didn’t look quite as pretty as the other three, but we were able to fit the bolt in. From the outside, you can’t tell what we had to do to make it fit. I’m not sure if this is a design flaw or just small tolerance for not being perfectly square. We tried the alternatives of adjusting the angles, but had to resort to cutting metal.

[See image gallery at overlandingadventures.forest2sea.com]

What’s Next?

In Part 3, we’ll install the biggest item on the roof rack.

The post FJ Cruiser Overland Build Part 2 appeared first on Forest2Sea Overlanding Adventures.

Overland and Exploration

Systems Engineering / Requirements Analysis

Throughout this series, I’m going to try to provide enough information for someone else who is looking to build something similar. We want you to take advantage of the homework we’ve done or learn from the mistakes we’ve made. At the same time, we don’t think you want to read a 50 page blog just on installing a roof rack. We’re more than happy to provide more information, so if there’s something you’re looking for, please leave a comment and we’ll provide the gory details!

Check out the really cool video that CrtrGrl made to share some of the fun we had putting it together:

 

Taking Apart our FJ

Next Steps

The post FJ Cruiser Overland Build Part 1 appeared first on Forest2Sea Overlanding Adventures.