428: Jonathan Ward on the Toyota FJ Cruiser & ICON 4x4

CAD (computer-aided design) files are digital 3D models used to design parts and assemblies. Refining CAD files is a common way to iterate on suspension geometry, mounting points, and fitment before building physical prototypes.

A solid axle is a suspension design where the left and right wheels are connected by a single rigid axle beam. Because both wheels share the same axle, it can feel less “car-like” over bumps than independent suspension, especially in terms of ride comfort and steering response.

“Wheelbase” is the distance between the front and rear axles. A shorter wheelbase generally makes a vehicle feel more agile and can improve turning, but it can also make the ride and stability feel less settled than a longer-wheelbase vehicle.

Four-wheel independent suspension means each wheel can move up and down without directly forcing the opposite wheel to move. This usually improves ride comfort and traction because the suspension can better follow uneven terrain while keeping the vehicle more stable.

Morrison is referenced as the company behind the suspension/chassis development used for 1947–1953 Chevrolet pickup applications. In custom off-road and restomod circles, Morrison is known for engineered chassis and suspension solutions that modernize classic trucks.

The Ford Bronco is a modern off-road SUV built around high ground clearance and strong suspension travel. In this segment, they’re discussing changes to ride height and chassis/suspension design to improve both off-road capability and on-road manners.

Ride height is the distance between the vehicle’s body and the ground. Lowering it by a few inches can improve stability and handling on-road, while raising it (or keeping it high) helps with ground clearance for obstacles off-road.

Ground clearance is the minimum distance between the underside of the vehicle and the road surface. More ground clearance helps prevent scraping the chassis, skid plates, or exhaust when driving over rocks, ruts, and uneven trails.

Four-wheel independence means each wheel can move up and down without being rigidly tied to the others. This improves ride quality and traction because one wheel hitting a bump doesn’t force the opposite wheel to move the same way.

A prototype is an early, test version of a vehicle or system built to validate design choices before production. Here, they’re talking about getting the first prototype finished to evaluate changes to the Bronco’s off-road and on-road behavior.

Fox Racing is a motorsports and off-road brand best known for performance suspension components and off-road gear. In this segment, they mention leaving Fox Racing and partnering with another suspension supplier for the Bronco program.

Ryger is a suspension brand referenced as being highly respected globally, with a U.S. presence tied to its sister line for two-wheel-drive vehicles. Here, they’re using Ryger to supply “icon specific suspension” for the Bronco-related project.

KW is a suspension brand name mentioned as Ryger’s sister line in the U.S. The segment uses it to explain brand recognition: U.S. buyers may know KW, while Ryger is the supplier now being used for this “icon specific suspension” application.

A nitrogen charge refers to pressurizing a shock absorber (or related hydraulic system) with nitrogen gas. The added pressure helps control damping behavior and can reduce issues like cavitation under repeated impacts.

Jounce is the suspension compressing (moving upward relative to the body) under load, and “bottom impact” is when the suspension reaches its compression limit. Tuning for jounce/bottoming helps reduce harshness and protects components during hard landings or bumps.

Steering architecture is the overall design of how the steering system is laid out—geometry, linkages, and how the wheels are guided. Changing steering architecture can improve off-road control (like bump steer and turning behavior) and also refine on-road feel.

“49 inch architecture” refers to a specific platform/suspension design framework measured around a 49-inch dimension (likely related to wheelbase, track, or structural layout). The speaker says they’re exploring working with Curry using that architecture, plus different steering geometry.

The Ford Mustang GT 5.0 Coyote is notable for its modern 5.0-liter V8 (the “Coyote” engine) that powers many late-model Mustangs. In this segment, they reference it as the current production evolution point for their steering/chassis development work.

Ford Racing is Ford’s performance parts and motorsport-focused organization. Here, the speaker complains that Ford Racing doesn’t share all the detailed engineering “subtleties” behind the production setup they’re trying to work with.

Suicide doors are doors that hinge at the rear (so they open opposite the usual direction) rather than at the front. They’re a distinctive styling choice on custom builds, but they require careful engineering so the door geometry and latch/hinge loads work correctly.

The B pillar is the vertical structural support between the front and rear doors (or between the windshield and the rear door area). When you stretch or redesign a two-door body into a four-door, the B pillar location strongly affects proportions, door sizing, and how the floor and roof structure must be re-engineered.

A carbon fiber roof cap is a lightweight composite panel used to reduce mass high up on the vehicle. The speaker connects it to improving weight distribution, which can help handling by lowering the car’s center of gravity and reducing the moment of inertia.

A hard top is a fixed, rigid roof structure (as opposed to a removable or convertible soft top). In custom builds, choosing a hard top affects structural design, crash/roll strength, and how the roof and floor are engineered to work together.

Body in white (BIW) is the vehicle’s unpainted body shell—typically assembled with panels and structural components before paint and final trim. It’s a key stage in fabrication because it’s where fitment, alignment, and structural geometry are verified before the build moves on to finishing.

A restomod is a restoration-and-modification approach: keeping the classic look or platform while updating it with modern engineering, parts, and drivability. The speaker says the market is oversaturated with restomod shops, implying many builds may be similar or not as thoughtfully engineered.

“Owner retention” means how many customers keep their vehicles/brand over time instead of switching to competitors. In the collector-truck and off-road world, it’s often tied to satisfaction with build quality, support, and long-term ownership experience.

“Rest of mods” appears to be the host’s shorthand for “restomod” culture—modernizing classic vehicles while keeping their original look and vibe. The key idea is that these builds are often tailored to a specific driving mood and audience, not mass-market utility.

A “generational investment” refers to the huge, multi-year development budgets automakers spend to design and refine a vehicle platform across successive model generations. That scale is why OEMs can engineer, validate, and optimize systems more deeply than small builders.

The “retro modern series” is a named build concept: taking a modern truck platform and reworking it into a classic-styled package. In this segment, it’s positioned as a deliberate alternative to copycat builds, starting with classic Chevrolet pickup generations.

This refers to a 2025 Chevrolet Silverado equipped with a 5.3-liter V8 and four-wheel drive, which is the modern donor platform for the builder’s retro-modern conversion. The 5.3 V8 is a common GM truck engine, and using it as a base lets the builder keep modern drivability while changing the exterior and some systems.

The Chevrolet C10 is a classic generation of Chevrolet pickup trucks, and it’s a common platform for restoration and customization. The podcast specifically mentions C10s and related variants (like K10, C20, K20) as starting points for builds, which highlights how these trucks share a family of dimensions and configurations. That makes the C10 line especially relevant when discussing how to source parts and plan projects.

ABS (anti-lock braking system) prevents wheel lockup during hard braking by modulating brake pressure. It improves steering control on slippery surfaces and reduces the chance of skidding.

“DoD” here is shorthand for GM’s Displacement on Demand, a system that deactivates some cylinders to improve fuel economy. The host suggests those cylinder-deactivation behaviors can be problematic on this platform, so they plan to address them in the conversion.

“Rebodding” (likely “rebodying”) means swapping or reworking the body shell so a modern chassis wears a different exterior. In this context, it’s how they’re turning a 2025 Silverado donor into a classic C-generation pickup look.

A limited run means a company produces only a small number of vehicles or a specific conversion package. It’s often used for specialty builds where parts, labor, or engineering time are constrained.

A chassis is the vehicle’s structural foundation that supports the body and drivetrain components. When a conversion uses a different chassis, it can throw off fitment and proportions, which is why “hack jobs” can look wrong.

“Derelict style” is a custom-build aesthetic that intentionally preserves or recreates a worn, battle-scarred look rather than restoring everything to pristine condition. In this context, it’s tied to keeping the original body appearance while making functional upgrades.

Track width is the distance between the left and right wheels on the same axle. Changing it (often via wheel/tire choices) can affect stability, steering feel, and how the vehicle sits.

The Dodge Ram is a full-size pickup truck line that’s been around for decades, and it’s frequently discussed alongside other major pickup families because of its long-running popularity. The podcast context points to how these trucks compare in dimensions and overall layout “since the late 1960s,” which matters for fitment, restoration, and customization. That’s why the Ram name comes up when talking about building or swapping components across generations.

CAN bus architecture is the vehicle’s network system that lets electronic control units (ECUs) communicate over shared wiring. If it’s engineered correctly, the car’s electronics behave as if they’re still in the original platform.

EPROM flash updates refer to reprogramming the car’s electronic control software (often via a dealer tool) by rewriting memory in the relevant modules. The point here is that the electronics remain compatible with normal dealer procedures.

An engine governor is a control strategy that limits maximum speed by restricting how fast the vehicle can go. Disabling or changing it is sometimes done for off-road or special-use builds, but it can affect safety and compliance.

Active suspension control uses sensors and actuators to adjust damping and/or suspension behavior in real time. The goal is to keep the vehicle composed over rough terrain and improve traction and stability.

ICON 4x4 is a specialty off-road customization brand known for building high-end, expedition-ready 4x4 vehicles. In this segment, the host ties ICON’s “original icon, FJ” launch and later customer-driven changes to how ICON builds and sells customized FJ-based trucks.

In automotive wiring, a connector is the mating plug-and-socket interface that allows wires to be joined or routed to a component. Connector quality matters because poor connections can cause intermittent electrical faults and can be difficult to troubleshoot later.

A wiring harness is the bundled set of wires and connectors that routes power and signals throughout a vehicle. In custom builds, the harness quality and design can affect reliability, diagnostics, and how cleanly the electrical system integrates with the rest of the truck.

The Mitsubishi Endeavor is an SUV model name, but in the podcast excerpt it’s used as a wordplay reference to “endeavor” meaning a complicated or costly project. The speaker mentions “wiring harness” costs and describes harnesses as expensive, using the model name as a humorous label for the situation. So the car name is being referenced more for the phrase than for technical details about the vehicle.

Icon is a custom-vehicle brand known for building restyled, modernized off-road and classic-inspired trucks. The host contrasts Icon’s approach with “fashion statement” builds, emphasizing craftsmanship and long-term ownership value.

Ravology is referenced as a company involved with Icon’s projects, specifically in relation to the relationship between the brands. The discussion frames it as part of a multi-company setup that collaborates on production and facilities.

Barrett-Jackson is a major collector-car auction company, and the Columbus sale is one of its event locations. These auctions are where rare or high-demand collector vehicles often change hands, making them a key marketplace for enthusiast builds and modern classics.

Singer is a well-known Porsche restoration and restomod brand famous for highly curated, bespoke builds. In this segment, the host says Singer is now part of a collective that includes Ravology and Icon, implying a coordinated approach to events and projects.

The Toyota FJ 40 is the classic Land Cruiser variant built for rugged, simple off-road use, with a body-on-frame layout and a reputation for durability. Here, the speaker describes buying FJ 40s, “dialing them in,” and reselling them—highlighting why this model is a popular collector and restoration target.

Granada Hills is a neighborhood in the San Fernando Valley area of Los Angeles, California. The speaker uses it as the location where they bought an FJ 40, grounding the story in a specific LA-area car-buying scene.

The Ford Granada is a mid-size car that’s referenced in the podcast as part of a story about where an FJ 40 was bought—specifically “Granada Hills” in the Los Angeles area. In this context, “Granada” is being used as a place name rather than as the car being discussed as a build or ownership subject. That’s why it appears in the conversation without the usual technical details.

A Ford F-250 is a heavy-duty pickup truck commonly used for towing, hauling, and off-road work. In the segment, the speaker mentions mounting a small lizard charm on the toolbox of his F-250, showing how the vehicle becomes part of his personal “carry it everywhere” story.

“Design study vehicles” are early, concept-stage prototypes built to test styling and engineering ideas before a program is finalized. “Pre-production fully functioning” implies these weren’t just mockups—they could operate and demonstrate real systems while the design was still being shaped.

Focus groups are small, structured panels of people used by automakers to gather feedback on design, features, and branding. In automotive development, they help decide what resonates with target buyers before production is locked in.

Triple wipers refers to a windshield wiper setup with three wiper arms/blades, typically used to improve visibility and coverage on certain windshield shapes. In the FJ Cruiser context, it’s one of the distinctive exterior details Ward says he contributed to during early design work.

The front grille surround is the trim or bezel framing the grille opening. It’s a styling detail that can strongly affect a vehicle’s “face” and brand identity, which is why Ward calls it out as part of his design contribution.

CALTY is Toyota’s design and development organization (often referenced as Toyota CALTY) that works on styling and product design direction. Ward contrasts his early design elements with how the project was later reworked after it moved to CALTY.

Jim Farley is a senior automotive executive who has held leadership roles at major automakers. In this segment, Ward mentions Farley being on the Toyota team during the FJ Cruiser-related work, then leaving to run Ford, framing how teams and leadership shifted.

A “SEMA mod” refers to a custom build intended for the SEMA show, where builders often focus on eye-catching styling and attention-grabbing features. The speaker contrasts typical SEMA builds (“bling”) with their goal to fully engineer the Bronco rather than rely on quick, cosmetic fixes.

CAD support means providing help with computer-aided design, where engineers use software to model parts and systems before anything is built. In a custom vehicle project, CAD is crucial for packaging, fitment, and designing brackets, bodywork, and mechanical components.

Nike is a consumer brand that also runs design and prototyping operations, which the speaker describes as having advanced manufacturing resources. The episode uses Nike as an example of how fast a concept can become a physical product when the right tooling and workflow exist.

Haas CNC machines are computer-controlled milling/turning tools used to manufacture parts from metal or plastic. The speaker’s point is that Nike has multiple CNC machines in-house, even though some people might think those machines aren’t available or don’t exist.

DARPA is the U.S. Defense Advanced Research Projects Agency, known for funding high-risk, high-reward technology development. The speaker uses it to describe work that can be more conceptual or experimental, which can affect staffing and project timelines.

The Toyota FJ Cruiser is a 2007-era retro-styled SUV known for its boxy, off-road look and body-on-frame roots. In this segment, the host discusses specific real-world usability issues he noticed when seeing a 2007 FJ Cruiser in person.

A power rear window is a rear glass panel that can be opened or closed using an electric motor. Removing it can change airflow and cabin comfort, which is why the speaker links the deletion to increased air buffeting.

Air buffeting is the uncomfortable, turbulent airflow that can shake or buffet the cabin and create loud wind noise. It often happens when openings (like windows) and body shapes don’t manage pressure changes well.

Ingress/egress awkwardness refers to the difficulty of getting in and out of a vehicle due to door layout and available clearance. With suicide-style rear doors, the open-door geometry can force awkward body positioning and reduce safe, clear pathways.

A tailgate is the rear door of an SUV or pickup that swings open to access the cargo area. The speaker is specifically complaining about how the suicide doors’ opening/closing interacts with the tailgate when loading luggage.

3D modeling is the process of creating a digital, three-dimensional representation of an object so it can be designed, modified, and visualized before manufacturing. Here, the speaker is describing how customers could use 3D modeling to create custom parts or designs for the aftermarket product ecosystem.

3D printing is a manufacturing method that builds parts layer-by-layer from a digital design, enabling rapid prototyping and potentially small-batch custom components. The speaker mentions it as part of a template-driven workflow for creating personalized designs.

File sharing is the process of distributing digital design files among collaborators so they can review, modify, and iterate on development work. In this segment, it’s mentioned as a “novel level” of collaboration for aftermarket development.

Matte colors are paint or finishes designed to reduce gloss, giving a non-reflective, “flat” appearance compared with standard glossy paint. The speaker says ICON originally used matte tones for a strategic reason, and that more colors are available now.

The Toyota FJ-40 is the classic, boxy Land Cruiser variant from the 1960s–1980s era that became an icon for simple, rugged off-road use. In this segment, the speaker is describing how the ICON 4x4 concept was meant to evolve the “modern form” of that original FJ-40 look and vibe.

“Mil-spec” refers to military-grade specifications—standards for materials, manufacturing, and performance that are typically stricter than normal consumer requirements. Here, the speaker uses it to describe their “new school” design package as technical and industrial-grade rather than flashy.

Powder coating is a finishing process where a dry powder is electrostatically applied to a surface and then cured in an oven to form a tough protective layer. The speaker connects it to Cardinal coatings’ expertise and to their oven-cure process for FJ bodies.

This is a specialized powder-coating formulation combining Teflon (PTFE) with polyester chemistry, using an SDIC hybrid approach. Powder coating is applied as a dry powder and then cured in an oven, and the speaker emphasizes it for durability against heat and harsh environmental conditions.

“Bonnet shops” is a slang term for low-end, quick-turn body/paint operations that may not deliver the same level of fit, finish, or durability. The speaker contrasts their approach with these shops, emphasizing their own process and coating durability.

Brembo is a performance-brake brand known for high-end calipers and rotors used on everything from track cars to premium street builds. Here, the host says the calipers and rotors are custom-specific to their vehicles, emphasizing that braking hardware is engineered as part of the whole build, not just swapped in.