Zack Roy's "Dr. Dirt" - FJ-40 Inspired Revolution 3.0 Chassis Build

Zack Roy's "Dr. Dirt" - FJ-40 Inspired Revolution 3.0 Chassis Build

Toyota Soul. WOD DNA. 427 Cubic Inches of Attitude. 

When Zack Roy of Lexington, Kentucky, came to us, he brought more than a vision—he brought a legacy. As a lifelong Toyota fan, Zack wanted his next build to honor the FJ-40s he drove off-road for years. He also needed the proven strength of a Wide Open Design Revolution 3.0 chassis.

The result is “Dr. “Dirt,” a four-seat surgical tool, built to cut through South Pittsburg woods, powered by a Mast Motorsports 427ci Gen V LT.

The Custom Craftsmanship: The FJ Reimagined
The "face" of Dr. Dirt is a custom-narrowed FJ-40 hood mated to a front bib hand-fabricated from 1/8" 5052 aluminum. We didn't just slap a grill on it; we shortened an original FJ-40 unit to match the aggressive, narrowed lines of the buggy. It’s a look that says "classic" while the performance says "future."

The Drivetrain: No Weak Links
A build this size requires serious muscle to stay agile. We backed the Mast 427 with a TH400 and an Atlas transfer case—a combination that laughs at torque. But the real magic is in the maneuverability. To make a four-seater handle like a short-wheelbase ripper, we equipped Dr. Dirt with Four-Wheel Steering tucked into Crane 14-Bolt axles with 40-spline RCV shafts. If the trail is tight, Zack just steers the rear.

Inside the Cockpit: The Baja Standard
Inside the Revolution 2.0 frame, comfort meets tech. Four heated PRP seats ensure the whole crew stays planted while the Radflo 2.0 coilovers and 2.5" bypass shocks soak up the hits. Navigation is handled by the Garmin Tread Baja Race GPS, giving Zack race-level trail mapping at his fingertips, while a full Rugged Radios suite keeps the conversation going over the roar of the LT.

Category Component Technical Specifications
Chassis WOD Revolution 3.0 4-Seater Platform; Built for 43" Stickies
Engine Mast Motorsports 427 Gen V LT; 625 HP
Exhaust WOD & Sanderson LT Block Huggers; TIG-welded Stainless U-bends
Cooling WOD Combo WOD 31" x 15.5" Radiator & SPAL Fan Package
Transmission TH400 With Winters TH400 Shifter
Transfer Case Atlas II 2-Stick Gear Driven
Front Axle Crane Axle 14-Bolt 5.13 Gears; Spool; 13-Bolt Cover
Rear Axle Crane Axle 14-Bolt 5.13 Gears; Spool; 13-Bolt Cover
Knuckles/Hubs Crane Magnum Unit Bearing Adapters; '05+ Unit Bearings
Axle Shafts RCV Performance Big Bell with 40-Spline Shafts (F/R)
Driveshafts 1410 Series WOD 1410 Drive Shaft Kits
Steering PSC / WOD Custom Full Hydro; WOD 24" Steering Column
Links 7075 Aluminum 1-1/4" Rod Ends; 7075 Aluminum Link Bars
Front Shocks Radflo Dual-Setup 2.0 Coilovers (14") + 2.5 3-Tube Bypass
Rear Shocks Radflo Dual-Setup 2.0 Coilovers (14") + 2.5 3-Tube Bypass
Bump Stops Radflo 2.0 2.0" Diameter x 2.0" Travel
Sway Bar Currie Anti-Rock Rear-mounted for stability
Tires Interco TSL SX 43" Sticky Compound
Wheels KMC Grenade 17" Aluminum Beadlocks
Brakes Wilwood / Crane Hydroboost w/ Wilwood Master Cylinder; Crane Lightweight Kit
Interior PRP Custom Heated Seats; 5.2 Harnesses
Armor 6061 Aluminum 3/8" Thick Belly Skid Plate
Recovery Warn / Halon Warn Winch (Front); (2) Halon Extinguishers
Lighting KC Lights Full Interior & Exterior LED Package

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