For this vehicle, our client wanted to add a lot more functionality and storage, tailored to his off-road uses.
This was a cool project for an awesome client of ours, who always brings us interesting and ambitious ideas for his growing fleet of impressive vehicles.
For this ICON FJ44, his wish list included: a significantly re-imagined rear storage system, thoughtfully compartmentalized for easy organization and access to various gear; rear HVAC for his dogs, who often travel with him; a sturdier and more utilitarian roof rack; a richer audio experience; plus some auxiliary lighting and accessories.
Our client had an ambitious wish list...
Our client had an ambitious wish list for this project, a customization of an already-custom ICON Toyota LandCruiser FJ44. Our video here describes this full project. Or to see our process in photos and captions, this page recounts the project details.
Our first major task was...
Our first major task was to figure out the rear storage and HVAC. Our client requested a highly-organized storage compartment system, as well as rear AC, since he often brings his dogs with him.
Our first major task was...
Our first major task was to figure out the rear storage and HVAC. Our client requested a highly-organized storage compartment system, as well as rear AC, since he often brings his dogs with him.
Based on the HVAC components’...
Based on the HVAC components’ dimensions, we started CAD design. In conjunction with this, in the vehicle, we taped off placeholder markings, to indicate what would go where.
Based on the HVAC components’...
Based on the HVAC components’ dimensions, we started CAD design. In conjunction with this, in the vehicle, we taped off placeholder markings, to indicate what would go where.
Once our dimensions and a rough layout...
Once our dimensions and a rough layout of storage bins was determined, we sent renderings to our client and then continued refining the CAD design.
Once our dimensions and a rough layout...
Once our dimensions and a rough layout of storage bins was determined, we sent renderings to our client and then continued refining the CAD design.
Upon client approval of the basic layout...
Upon client approval of the basic layout, we finalized the CAD layout with more details, such as L-track, AC vents, locking mechanisms for some of the bins, and corresponding hardware (as well as any tolerances required for those details and for paint), before CNC-milling a rough mockup.
We CNC’d a full-scale mockup in wood...
We CNC’d a full-scale mockup in wood, to test fitment in the vehicle for any further tweaks.
Then we started CNC’ing...
Then we started CNC’ing the full cargo system apparatus in wood.
Then we started CNC’ing...
Then we started CNC’ing the full cargo system apparatus in wood.
We installed handles, locks,...
We installed handles, locks, hinges, channels for L-track, and hardware, to test overall fit and functionality.
We installed handles, locks,...
We installed handles, locks, hinges, channels for L-track, and hardware, to test overall fit and functionality.
With the full design and placement...
With the full design and placement finalized and approved by our client, we removed it from the car for final refinements and paint. At the same time, in the car, we installed the HVAC evaporator and air compressor, and corresponding lines and appendages.
With the full design and placement...
With the full design and placement finalized and approved by our client, we removed it from the car for final refinements and paint. At the same time, in the car, we installed the HVAC evaporator and air compressor, and corresponding lines and appendages.
A bedliner finish was applied...
A bedliner finish was applied to all of the storage system panels, as shown, then it was re-installed in the FJ44. Each bin has rubber bulb seals around the edges for a tight seal, and ball catches on all the lids, for nice solid closure. And L-tracks run around the perimeters of the bins for additional tie-down capability.
A bedliner finish was applied...
A bedliner finish was applied to all of the storage system panels, as shown, then it was re-installed in the FJ44. Each bin has rubber bulb seals around the edges for a tight seal, and ball catches on all the lids, for nice solid closure. And L-tracks run around the perimeters of the bins for additional tie-down capability.
For the AC vents in this rear area...
For the AC vents in this rear area, these are the same style that ICON installed in the front cabin area for the passengers, but with a slight modification to remove the manual-adjust open/close option, to prevent the client’s dogs from inadvertently turning off the AC if their paws hit the vents.
For the AC vents in this rear area...
For the AC vents in this rear area, these are the same style that ICON installed in the front cabin area for the passengers, but with a slight modification to remove the manual-adjust open/close option, to prevent the client’s dogs from inadvertently turning off the AC if their paws hit the vents.
The locking long center bin...
The locking long center bin was one of the first requests our client had mentioned for this rear storage system, for safe storage of rifle or long guns. This bin connects to a center console in the rear seats of the cabin, housing cup holders and another locking storage bin easily accessible from the rear passenger seats.
The locking long center bin...
The locking long center bin was one of the first requests our client had mentioned for this rear storage system, for safe storage of rifle or long guns. This bin connects to a center console in the rear seats of the cabin, housing cup holders and another locking storage bin easily accessible from the rear passenger seats.
...we redesigned the tailgate latch...
Additionally, we redesigned the tailgate latch, as shown here.
...we redesigned the tailgate latch...
Additionally, we redesigned the tailgate latch, as shown here.
This next series of photos shows the significant audio upgrade we performed in the FJ44.
...wanted his audio to have a more robust presence...
The standard audio system in an ICON FJ is a fairly no-frills set-up, with a head unit mounted low and out of sight between the front seats. Our client wanted his audio to have a more robust presence, both aurally and visually. We selected a Pioneer touch screen head unit, then CAD-designed and CNC’ed an acrylic housing to surround it.
...wanted his audio to have a more robust presence...
The standard audio system in an ICON FJ is a fairly no-frills set-up, with a head unit mounted low and out of sight between the front seats. Our client wanted his audio to have a more robust presence, both aurally and visually. We selected a Pioneer touch screen head unit, then CAD-designed and CNC’ed an acrylic housing to surround it.
We installed new defroster plates...
We installed new defroster plates on either side of the head unit, and then matched the dash finish for a seamless appearance within the ICON look-and-feel.
We installed new defroster plates...
We installed new defroster plates on either side of the head unit, and then matched the dash finish for a seamless appearance within the ICON look-and-feel.
For well-placed location and directionality...
For well-placed location and directionality of high-frequency sound, deep chamber Scan-Speak tweeters were mounted under the dash, housed in bullet-shaped pods we CAD-designed and 3D-printed in-house.
...we fabricated kick panels...
For mid-range speakers, we fabricated kick panels, situated low in the cabin just above the floor near the front doors. For an integrated finish, these were Linex bedlined to match the ICON’s floor.
...we fabricated kick panels...
For mid-range speakers, we fabricated kick panels, situated low in the cabin just above the floor near the front doors. For an integrated finish, these were Linex bedlined to match the ICON’s floor.
Then for low-frequency output...
Then for low-frequency output, we designed a new enclosure to house the subwoofer. We installed this in the existing ICON location under the driver’s seat; however, our treatment of this seat base was comprehensive, to get a true subwoofer response from it, for the perfect amount of bass to best complement this overall audio system.
Then for low-frequency output...
Then for low-frequency output, we designed a new enclosure to house the subwoofer. We installed this in the existing ICON location under the driver’s seat; however, our treatment of this seat base was comprehensive, to get a true subwoofer response from it, for the perfect amount of bass to best complement this overall audio system.
And for rear fill...
And for rear fill, we installed two marine-grade speakers at the back of the FJ44, which we mounted to the roll bar.
...we selected JL Audio amps...
To power this upgraded audio system, we selected JL Audio amps, housed in a custom bracket under the passenger seat.
Our next big element to this project was the roof rack. Our client wanted to maintain the look and essence of the ICON rack, but modify it to add a platform and tie-down system, to accommodate significantly greater weight-bearing capacity, plus auxiliary lighting.
Shown here is the original ICON rack...
Shown here is the original ICON rack. Our client wanted to stay faithful to the feel of this, but wanted something considerably more substantial, so we kept the original and modified it. After removing it from the FJ44, we sandblasted it to remove the existing powder-coated finish.
Shown here is the original ICON rack...
Shown here is the original ICON rack. Our client wanted to stay faithful to the feel of this, but wanted something considerably more substantial, so we kept the original and modified it. After removing it from the FJ44, we sandblasted it to remove the existing powder-coated finish.
Next we fabricated a steel base...
Next we fabricated a steel base for adding decking panels, then CAD-designed slotted decking with L-track channels.
Next we fabricated a steel base...
Next we fabricated a steel base for adding decking panels, then CAD-designed slotted decking with L-track channels.
Similar to how we approached our initial mockup...
Similar to how we approached our initial mockup of the rear HVAC+storage system, we CNC’ed a rough prototype in wood before milling the final version in aluminum.
Similar to how we approached our initial mockup...
Similar to how we approached our initial mockup of the rear HVAC+storage system, we CNC’ed a rough prototype in wood before milling the final version in aluminum.
...we proceeded to CNC-mill the final version...
After true-ing our fit and finalizing our CAD design per the wood prototype, we proceeded to CNC-mill the final version of the roof rack in aluminum.
...we proceeded to CNC-mill the final version...
After true-ing our fit and finalizing our CAD design per the wood prototype, we proceeded to CNC-mill the final version of the roof rack in aluminum.
We CNC’ed the final decking...
We CNC’ed the final decking in 1/4” aluminum, with our steel base, then welded the various components together and to the original rack.
We CNC’ed the final decking...
We CNC’ed the final decking in 1/4” aluminum, with our steel base, then welded the various components together and to the original rack.
Final details on the rack...
Final details on the rack included aluminum perches for mounting LED light bars. And the L-track was installed.
Then the roof rack was powder-coated...
Then the roof rack was powder-coated in black, filled throughout with stainless steel fasteners, and lighting was installed.
Then the roof rack was powder-coated...
Then the roof rack was powder-coated in black, filled throughout with stainless steel fasteners, and lighting was installed.
The final modified roof rack...
The final modified roof rack was re-installed on the FJ44 – still honoring the original ICON rack, but now able to withstand being stood or kneeled on, and capable of storing much more gear.
Additionally, we added several other electrical upgrades and custom features to the FJ44, as shown in this last series of photos.
...our client wanted to add a powerful spotlight...
On the hood, our client wanted to add a powerful spotlight. Whelen, a leading manufacturer of lighting for emergency services, had just released a new searchlight with remote joystick control. We explored exterior locations that might work, and selected a placement on the driver-side fender near the front windshield, where it would not interfere with the driver’s view and would have full 360° maneuverability.
To mount it in this location...
To mount it in this location, we 3D-scanned the fender, and then CAD-designed and 3D-printed a custom snorkel to fit flush against it.
To mount it in this location...
To mount it in this location, we 3D-scanned the fender, and then CAD-designed and 3D-printed a custom snorkel to fit flush against it.
To mount it in this location...
To mount it in this location, we 3D-scanned the fender, and then CAD-designed and 3D-printed a custom snorkel to fit flush against it.
For the snorkel finish...
For the snorkel finish, we matched the FJ44’s exterior surface, and then we installed the controller in the cabin cockpit.
For the snorkel finish...
For the snorkel finish, we matched the FJ44’s exterior surface, and then we installed the controller in the cabin cockpit.
The Whelen controller’s placement...
The Whelen controller’s placement was on the front face of a center console that we also custom-designed in CAD and CNC’ed. And then, similar to some of the storage compartments in the rear cargo system, the top of this console included a combo lock.
The Whelen controller’s placement...
The Whelen controller’s placement was on the front face of a center console that we also custom-designed in CAD and CNC’ed. And then, similar to some of the storage compartments in the rear cargo system, the top of this console included a combo lock.
...we also designed a custom switch panel...
Under the dashboard, we also designed a custom switch panel. We positioned this in the same location where ICON had placed a smaller panel for a trio of three ARB air locker switches. Based on the shape of that panel, we created a longer switch panel in CAD (essentially equivalent to taking the existing panel and extruding it out to a new length), to house additional switches for some of the custom features we’d added.
...we also designed a custom switch panel...
Under the dashboard, we also designed a custom switch panel. We positioned this in the same location where ICON had placed a smaller panel for a trio of three ARB air locker switches. Based on the shape of that panel, we created a longer switch panel in CAD (essentially equivalent to taking the existing panel and extruding it out to a new length), to house additional switches for some of the custom features we’d added.
We 3D-printed the new switch panel...
We 3D-printed the new switch panel, and re-installed the three ARB switches, then added the climate controls and auxiliary lighting switches, for fog lights, roof lights, reverse lights, side and rear flood lights, as well as seat-warmer buttons, and two USB ports. Many of these were relocated from clumsy ICON locations.
We 3D-printed the new switch panel...
We 3D-printed the new switch panel, and re-installed the three ARB switches, then added the climate controls and auxiliary lighting switches, for fog lights, roof lights, reverse lights, side and rear flood lights, as well as seat-warmer buttons, and two USB ports. Many of these were relocated from clumsy ICON locations.
Switches were custom-made...
Switches were custom-made, then we finished the panel to match the ICON dash, and installed it along the under-dash contour for a clean, integrated fit.
Switches were custom-made...
Switches were custom-made, then we finished the panel to match the ICON dash, and installed it along the under-dash contour for a clean, integrated fit.
Also along the dashboard...
Also along the dashboard, on both the driver’s side and passenger side, we added universal phone mounts by RAM. We CAD-designed custom bases for these, which were CNC-machined in stainless steel.
Also along the dashboard...
Also along the dashboard, on both the driver’s side and passenger side, we added universal phone mounts by RAM. We CAD-designed custom bases for these, which were CNC-machined in stainless steel.
...we installed a flashlight and fire extinguisher...
And on the floor between the front seats, under the dash, we installed a flashlight and fire extinguisher.
...we installed a flashlight and fire extinguisher...
And on the floor between the front seats, under the dash, we installed a flashlight and fire extinguisher.
We installed additional fire extinguishers...
In addition to the traditional fire extinguisher between the front seats, we also installed some fire-stick-style extinguishers to the roll bar in a few locations – in the mentality of “Two is one and one is none,” these provide an additional safety measure, and if deployed, they cause less residue than a traditional fire extinguisher. We also added gasket seals to all of the doors, for tight seals throughout the vehicle.
We installed additional fire extinguishers...
In addition to the traditional fire extinguisher between the front seats, we also installed some fire-stick-style extinguishers to the roll bar in a few locations – in the mentality of “Two is one and one is none,” these provide an additional safety measure, and if deployed, they cause less residue than a traditional fire extinguisher. We also added gasket seals to all of the doors, for tight seals throughout the vehicle.
The wiring for our custom work...Under the hood, we also added an Anderson 300-amp jumper plug and winch connector.
The wiring for our custom work required some deft wire-running and well-organized fuses, which would end up neatly concealed and virtually unseen in the finished vehicle. Since there’s no interior carpeting in the FJ44, many wires needed to be handled — safely, smartly, and clearly-marked — in various locations situated under the dash and under the seats and floor of the vehicle.
The wiring for our custom work...Under the hood, we also added an Anderson 300-amp jumper plug and winch connector.
The wiring for our custom work required some deft wire-running and well-organized fuses, which would end up neatly concealed and virtually unseen in the finished vehicle. Since there’s no interior carpeting in the FJ44, many wires needed to be handled — safely, smartly, and clearly-marked — in various locations situated under the dash and under the seats and floor of the vehicle.
The wiring for our custom work...Under the hood, we also added an Anderson 300-amp jumper plug and winch connector.
The wiring for our custom work required some deft wire-running and well-organized fuses, which would end up neatly concealed and virtually unseen in the finished vehicle. Since there’s no interior carpeting in the FJ44, many wires needed to be handled — safely, smartly, and clearly-marked — in various locations situated under the dash and under the seats and floor of the vehicle.
...we also added an Anderson 300-amp jumper...
Under the hood, we also added an Anderson 300-amp jumper plug and winch connector.
...the interior seats were re-upholstered...
And all of the interior seats were re-upholstered in leather.
...we stamped a new custom set of keys...
Among the finishing touches, we stamped a new custom set of keys for our client, all labeled and with a simple clean look.
Here’s the finished FJ44...
Here’s the finished FJ44, out-and-about for some off-road adventuring.
Here’s the finished FJ44...
Here’s the finished FJ44, out-and-about for some off-road adventuring.
Here’s the finished FJ44...
Here’s the finished FJ44, out-and-about for some off-road adventuring.
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