Super Duty Dana 60 And Sterling 10.5 Axle SAS Prep // FJ Cruiser Solid Axle Swap!! 

this channel deserves a lot more credit. you wheel harder than anyone else ive been following for awhile

i think this channel will get better with this mod as well, for your viewership, itll be the hardest run fj setup on youtube

You should do a video on the back story of Ken! The man, the myth, the legend! Always wondered what you do for a living to be able to travel and wheel so much plus have the extra cash for crazy awesome modes. I always assumed you were a computer programmer, the ability to work wherever, whenever, but then again you have some amazing mechanical skills and knowledge, so I’m puzzled/amazed! Thanks for the amazing content as always!!!

Just for everyone doing this project, do not cut the rear leaf pack mounts a thousand times, just cut into the two welds on either side with an angle grinder and hit it off with a hammer. 4:54-7:10 in the video.

Wow, 42's and 1 ton axles, shit just got real. cannot wait!

Love the great attitude, along for the ride.

Ive never seen anybody take off spring perches the hard way before. Cheers you got more energy than me. Looking forward to seeing you and your fj defeat busywild. I do enjoy watching the vids because of your great attitude. Following your ton swap. Thank you!!

This is awesome! As I was watching your previous videos I made a couple of comments that referred to your independent suspension. I was in very impressed with the performance of your rig but always cringed when you were going over rough obstacles. I knew there would come a day where you would need a serious upgrade and then you drop this video!

WOW! I am so impressed with your skills!!! I’ve always been impressed but this video shows a whole new level of straight up skill!!!

Definitely hanging around for the ride. Great work! Looking forward to the results!

Awesome!! Can't wait to see the end result!😲

This is going to be a monster of a build. Great content!!!

So awesome! what a great upgrade for your FJ

excited to see this turn out!

Your attitude is awesome for such grueling work. Keep the vids coming!

Cannot wait to see this build come together man... Awesome!

You're a madman and I love it! Keep up the excellent content! Can't wait to see the results.

Great work man

this is really cool man. i can't wait to see how this thing progress

Great stuff, Ken, we all can't wait for the next vid!

Stoked to follow this

Impressive job !!! Can’t wait to see them on the Fj.

I'm shocked and impressed.

Wow~ Great project. I can't wait to see the results and the performance it will bring...

What a project, good luck

Love your videos, adventurous with both offroading and with the modifications on your FJ !! Great inspiring content, keep it up !!

Can't wait tonsee the end of this build I'm subscribed

Ken, you’re the real deal! Awesome content!

Wow hard work keep it up. Your doing a great job. Can’t wait to see the project finished. Cheers

Talent and patience makes a tough job look easy. Well done.👍

love your channel! keep it up

So glad I found this! Going to be following the entire build. The step by step is very helpful for me, I have a similar plan for my GX and the platform is very similar to the FJ. Thanks!

Pretty excited to see where this goes. I'm picking up my FJ this week, going to go with a 3 inch lift and 33s until I can price up a SAS from maybe an 80 series.

Really envy your good natured perseverance. I have the perseverance, but I don't think I could have done that job without quite a few "ah, for f***s sake" getting onto the video. Great work.

Great work!

Man you're a hell of a go getter done guy! That was some work. I've been looking at them Jimny's LOL I like what you got lots better Good Luck To You Man, Peace

This FJ is going to be sick!!

Metabo with super slicer disks would reduce a lot of time. Starting a bad ass build for sure.

New to the channel. Going down the line watching every video as we speak. Just wanted to say thank you for the honest video and content all together. I hate when people leave stuff out to make excuses for damage or bad decision. As a new guy in the off-road scene I appreciate any knowledge I can soak up and this channel is for sure going to give me that.

This is some REAL shit, you are on FIRE! Can't wait to see this!

Ken, this is going to be an amazing transformation. You've done some amazing stuff with your current set up and you should have a much larger following. This build will put you in a whole new dimension, Utah Yota level with 42's. Thanks as always for all the effort you put into your videos and taking the time to show us all what you are doing. Can't wait to see how this continues along. Cheers

I will be doing this to my Explorer sport one day soon so thanks for more inspiration and knowledge. Im a noob and will learn a dnd on it all myself.

Can we say Patience and perseverance? You are going to need all that beef to drive those skyscraper 42s. Excited for you and for the videos ahead. Thanks for letting us join you on this build. P.S. bunches more sculpture material too! Lol

Those are some pretty nice wheels

Very cool! I had similar thoughts with my FJC. Wheel it, break some shit, then go tons. But I ended up cutting up my FJ40 to build a 45 on tons. Lexus v8, linked, bagged, blah, blah, blah. I am so glad you are documenting this. Your truck is awesome. Your channel rocks. Keep it up man!!!

subscribed just for this build session. I have a 06 4runner so the process would be similar. Keep at it!

The rear spring perched can be removed by cutting the weld with a cut of wheel.

I got the same setup on my fj and love it.

Wooow! This is insane! Cant wait for the next vid.. really wish you can have it 3xs a week for this build..

That’s awesome!

Well your doing it. Just like you said. Good work. Am looking forward to the rest of the build. C c Williamston mi

those polished beadlocks look rad too

I think you’ve gone crazy! Don’t get me wrong because I really like what you do but this is pushing it to another level! I can’t wait to see the results. That is going to be one bad ass FJ.

The most METAL video so far mate \_/ deserve some Grind Core Metal music :) awesome !!!!! Thanks for sharing

Thanks again sir for this awesome build to show us, again just wish it was on a 3 gen tacoma orsb so I can see how I wish my truck can become with alot of elbow grease and some money, and little imagination lol thanks again I'm sure it's going to turn out outstanding.

Oh yea buddy!!!!! Nice!!!! No more broken tie rods!!!!

They might not just bolt up but that’s where FlexTape comes in handy. ;-)

wow !! you dont just wheel harder than most !!!!! great content

Damn, Ken, now I know I won't be able to wheel with you when I get out West due to my 34 inch tires and your gazillion inch tires! I'll still follow and save my money to catch up!!

Thin metal compared to a battle ship! The parking brakes are bigger than the brakes on my 66 CJ-5 that I owned years ago. That's a a big job Ken I'm tired just watching you work. Looking forward to watching the progress.

Doing an awesome job!!! N getting noticed!!!!

Love your channel, trying to go back and like all the videos I watched (and enjoyed very much) since I am watching them on a shared smart tv so I was not logged in. Thought I’d mention when you reinstall those calipers pay attention that you get the caliper on the correct side otherwise the bleed screw will be on the bottom and you won’t be able to bleed the air out of them properly ;) I’m a Master Ford tech and I see it fairly often when customers work on their own vehicles not saying you would make that mistake yourself. Can’t wait to see your FJ back on the trail and hopefully I can wheel with you one day with my FJ

I cannot believe that you used a sawzall and a grinder to cut everything off those axles. That's dedication.

Just in case no one has mentioned it in the last year, all you have to do to remove those rear spring perches is cut the welds on the sides!!! Takes like 15 minutes, haha. Was fun watching you hack away at them though, Gotta learn somewhere!

Good luck with the build the cutting is a pain with the right tools... the struggle is real 😫lol

I definitely cant wait to see how this project turns out. Doing a SAS has been in my future plans as this would make the FJ complete. I've priced it out with shops and they are asking about $15-20K to complete it. Good luck!

Me here watching this with no plans of ever off-roading while staying 100% entertained 🤣

Nice. I think you and Eric will have the biggest FJ's out there. Looking forward to the step by step videos. Just got back from EJS. 40's are the new 35 and 42's the new 37. I think I was the only rig down there on 33's. The trails are getting extremely ripped up with all the big rigs for sure

I can already imagine that FJ is going make any trail look easy

Yes!

Fine... I'll subscribe. I just want to see the FJ do Busywild again on 40s.

It's tough grinding job!

Some mad skills there. I’d be pretty timid about SASing mine.

Хорошая работа !

The front axle looks more like a Dana 50 instead of 60, any way this is an awesome upgrade...good job!!

This is hard project to tackle. I cant wait to see what else your garage builder skills hold. Didn't see a welder in the background, unless its in one of the new boxes!

“Just gonna remove the brake lines. LOL. Up here in the great white salt shaker , that rarely happens.

Just watched your Busy wild video Ken. As I said there, your positive attitude is amazing & inspiring. Looking forward to many more awesome videos. Bless you Sir. Also, what might you have in mind for Lockers in this axle build? Air / Electric? Good 'ol Detroit diffs, maybe a Torsen diff??

Gonna be sad to see you leave the IFS gang! There was some hope of us non-crawler super builds of living precariously through your craziness on the trials! (Almost achievable). I’m think I should have gotten the Jeep instead ) Certainly there will be some amazing and otherwise not accessible places we will be seeing here so that will be really cool. Maybe some snow stuff this winter? You’ll be able to go almost anyplace with those giant tires locked up. Maybe visit some attainable trails on occasion too?

machinist tip; use some Engine oil ( new or used) on your cutting blade and work , it will greatly reduce cutting time and eat right through the metal being cut.

Amazing!! looking forward to see the full build. What is your plan for engine and transmission? and what gear ratio you will be running in those axles?

Just seeing this obviously way late but you should use a cutoff wheel on the spring pad welds. Then hit it with a hammer. Its just a weld on each side.🍻

Glad I snagged a plasma. Went through hundreds of discs prior. Still need angle grinder and Reciprocating saw sometimes but nice to have both. Have you picked one up since?

Excited to see the process and end result! Cant you normally just use a grinder to cut the welds on the axle brackets and then hammer them off? Always has saved us a lot of time!

What a pleasant surprise! I'm happy that someone is making a YT series on this. Why did you go with the sterling over like a 14 bolt? What lockers are you using, ARB's again?

Don't know if it's been said but I always just used a cutoff wheel to cut the welds on the brackets at the tube it's less work ,time and money

What an adventure to build fj with 1 ton. I was thinking, how awesome if you got together with Paul @fabrats and have him weld it up all together. I'm thinking about 1 ton also for my fj, but started to think maybe my fj40 would be a better project, and easier to link ( i think it might be easier lol) . Looking forward to following this build 👍👍 . Curious, you still going out to join us at Rubithon this year?

Its Happening !!!

Let me know if you wanna part with your Dobinsons! Also, any reason why you’re swapping the rear? Is your FJ an ‘07? I’m curious to see how this turns out.

Just recently picked up the exact same axles, on the sterling 10.5, what 4 tooth socket did you have on to take the wheel bearing off? Thanks

You still happy with the Metal tech front bumper? Trying to decide between it and a Resz. If you haven't had any approach issues with it I won't. I'm not a fan of trail fixes

I've never seen someone do so much with a sawsall!

Just did this on my 2021 JL DIESEL . Even with a respirator, I was blowing black boogers for a week 😂

I have a similar setup and was wondering what to do about the lugs being different thread pitches between the front and rear axles. I was wondering if I could just pop out the lugs and replace them with the same as the front? What are you doing about this?

Boss would say those discs are still good lol 😆. Jk but for real grinding like this is no joke and absolutely no fun worked at local train yard for Cathcart railway and we had to carbon arc the rails off the floors then grind all the old welds that was left talk about a back breaker.

New to your channel are u in Phoenix area?? Interested in the SAS & rear sterling swap

If you had to do it again, what would you do differently?

How can you tell the roofer Eve between a Dana 60 & Dana 50

Buy an axle from the northeast, sometimes the mounts are already removed 😂

Will you be upgrading to a new larger motor? V8?