You Won’t Believe How Much It Costs to Build a Custom 1 Ton Toyota FJ40 Land Cruiser

Building a fully custom FJ40 Land Cruiser isn’t for the faint of heart or light of wallet, as Austin Niemela discovered during his epic year-and-a-half build. When he finally tallied up the receipts, the numbers were eye-opening - even for someone who did most of the metalwork himself.

Austin started with a $5,000 basket case FJ40 that was completely rusted out with no drivetrain and a trashed interior. But finding these classic Toyota rigs in any condition has become increasingly difficult, making even a project truck worth the investment.

What followed was one of the most comprehensive builds you’ll see, with Austin documenting every dollar spent along the way. What he ended up with was a 1 ton, linked, LS engine early Cruiser on 40s.

Just how much did it cost? The final tally came to about $50k! And he saved a lot of cash by doing a lot of the work himself. Breakdown below:

The suspension setup alone would make most wheelers’ wallets weep. Austin went with a three-link front and four-link rear setup using RadFlo 16" remote reservoir coilovers with dual-rate springs, dropping $2,800 on the shocks. The link bars from Summit Machine added another $2,300, while the billet rod ends tacked on $1,800 more. After discovering the rig needed a sway bar during testing, a TK1 Racing rear unit cost another $600. Add in bump stops and limit straps, and the suspension system alone hit nearly $8,000.

Under the hood sits a rebuilt 5.3L LS from a ‘01 Tahoe paired with a 4L60E transmission. Austin bought the entire donor vehicle for $1,700, but the engine needed a complete rebuild with new pistons, rings, cam, lifters, and machine work totaling $4,000. The aggressive Texas Speed cam gives it that distinctive lope that makes heads turn on the trail.

The axles represent another major expense category. Austin sourced a Dana 60 front and Sterling 10.5 rear from a ‘03 Ford F-350 for $1,000, then completely rebuilt them with 5.38 gears, Grizzly lockers, new bearings, seals, and Moto-Built covers. The total axle investment reached $5,200, but these bulletproof 1 ton axles can handle the V8 power and 40" Cooper Discoverer STT Pro tires without breaking a sweat.

Inside the cabin, Austin went upscale with Corbeau seats front and rear costing $1,100, plus a digital AutoMeter instrument cluster for another $1,100. The modern gauge cluster transforms the interior appearance and functionality compared to the original analog setup. A complete sound system with touchscreen head unit, speakers, and wiring added $600 to the build.

The 40x13.5 Cooper tires mounted on Dirty Life beadlock wheels were a Facebook Marketplace steal at $2,000 for the nearly-new set. Austin’s timing was perfect, snagging wheels and tires that had only seen two trail runs. Finding deals like this can significantly impact your build budget, especially on big-ticket items like rubber and wheels.

Paint and bodywork consumed $3,600 in materials alone. The FJ40 needed extensive metalwork including floor replacement, rocker panels, quarter panels, and front fenders. Austin fabricated all the replacement panels himself, saving thousands in labor costs. The truck received a complete sandblast, epoxy primer inside and out, plus Raptor liner on the interior and undercarriage.

The fabrication work represents the biggest cost savings in the build. Austin estimates he saved $20,000-$30,000 by building everything himself - from the roll cage and rock sliders to bumpers, shock mounts, seat brackets, and axle trusses. During COVID-19, steel prices skyrocketed, with Austin spending roughly $3,000 total on raw materials.

Even miscellaneous items add up quickly on a build this comprehensive. Hardware alone probably hit $1,000, with every single bolt replaced. Add in items like the Smittybilt XRC 9500 winch, Rotopax fuel cans, Hi-Lift jack, dual air compressor setup, IceCo fridge, and countless small parts, and the miscellaneous category easily reaches four figures.

Austin’s final tally came to just over $50,000 in parts - a staggering number that reflects the comprehensive nature of this build. However, considering the quality of components and the fact that he fabricated most of the custom metalwork himself, the number becomes more reasonable. A similar build using purchased fabrication would likely exceed $80,000.

The time investment proved equally substantial, with Austin working over 40 hours per week for more than 18 months. This became his full-time job, requiring dedication that goes beyond typical weekend warrior projects. The complexity of custom fabrication, engine rebuilds, and complete chassis modifications demands both skill and patience.

For wheelers considering a similar build, Austin’s experience offers valuable insights. Having your own fabrication capabilities provides massive cost savings but requires significant time investment. Buying complete donor vehicles can be more economical than sourcing individual drivetrain components. Finding deals on used wheels, tires, and other components can meaningfully impact your budget.

Building a custom FJ40 to this level requires serious commitment, both financially and time-wise. But for those with the skills and dedication, the result is a truly unique rig that reflects your personal vision and capabilities. Austin’s build proves that with enough determination and fabrication skills, you can create something truly special - even if it costs more than most people’s houses.

You can follow Austin’s adventures and future builds on his Instagram where he continues documenting his off-road projects and custom fabrication work.