The desert sun beat down mercilessly as I crested the sandy ridge in my stock Hilux, already feeling somewhat inadequate about my off-roading credentials. That’s when I first laid eyes on Tinman.
“Holy sh–” I muttered under my breath, grabbing for my camera. It wasn’t just the chopped roof that grabbed my attention, though that radical modification alone would have been enough. It was the entire package – a Toyota FJ Cruiser transformed so completely that it barely resembled its factory origins, yet somehow retained the soul of what makes an FJ special.
As its owner Matt carefully navigated a particularly gnarly section of the Simpson Desert crossing, the vehicle’s significantly shortened wheelbase and aggressively chopped roofline created a silhouette unlike anything I’d seen before in the Australian 4×4 scene. This wasn’t just a modified vehicle; it was automotive sculpture that could also conquer terrain that would make standard 4x4s whimper.
That chance encounter three years ago sparked my obsession with what has become one of Australia’s most controversial and celebrated custom builds. After tracking Matt down for months, I finally convinced him to share the complete story of Tinman’s creation, from initial concept to the trophy-winning beast it is today.
The Man Behind the Machine
“Most people thought I’d lost my bloody mind,” Matt chuckled as we shared beers at his Brisbane workshop. Grease-stained hands wrapped around his stubby, he gestured toward the gleaming FJ parked in the corner. “My wife included. When I took a perfectly good $40,000 vehicle and started cutting the roof off, let’s just say it wasn’t a popular decision at home.”
At 42, Matt Harrison doesn’t fit the stereotype of a radical custom builder. A structural engineer by trade, his methodical approach to problem-solving seems at odds with the risk-taking spirit needed to dramatically reshape a modern 4×4. Yet this professional background proved to be the perfect foundation for such an ambitious project.
“The engineering principles had to come first,” he explained, pulling out meticulously detailed CAD drawings showing load paths and structural reinforcements. “You can’t just chop six inches out of a unibody vehicle and expect it to survive the punishment of serious off-roading. Every cut required compensation elsewhere.”
Matt’s journey with Toyota’s cult classic began innocently enough. After purchasing the FJ Cruiser new in 2013, he started with the usual modifications – a modest lift kit, larger tires, and a few recovery accessories. But while most enthusiasts would stop there, satisfied with incremental improvements, Matt found himself sketching more radical ideas during lunch breaks.
“I’ve always been drawn to the classic proportions of early Land Cruisers and International Scouts,” he explained. “Modern 4x4s have lost that purposeful, compact stance. I kept thinking the FJ Cruiser was so close to recapturing that spirit, but the greenhouse was too tall, the wheelbase too long.”
From Concept to First Cut
The transformation from stock FJ Cruiser to the vehicle now known as Tinman didn’t happen overnight. Matt spent nearly a year planning, measuring, and second-guessing before making the first irreversible cut.
“That first cut was terrifying,” he admitted, wincing at the memory. “I’d spent months reinforcing the structure with a custom internal roll cage, but cutting through the roof of your daily driver still feels like madness.”
Working nights and weekends in a rented garage space, Matt began the painstaking process of removing six inches from the roof height while simultaneously shortening the wheelbase by ten inches. This dual modification required completely rethinking the vehicle’s structure, including building custom B-pillars and extensively reinforcing the chassis to handle the altered load paths.
“I ruined three angle grinders and went through so many cutting discs that the local hardware store started ordering extras just for me,” he laughed. “My neighbors thought I was building a submarine or something in there – the noise was relentless for weeks.”
The vehicle sat untouchable during the 2019 Brisbane floods, raising Matt’s workshop anxiety to fever pitch as water crept toward his half-completed project. “I was checking the water levels hourly, ready to somehow drag this roofless, immobile shell to higher ground. Thankfully, it stayed dry by about six inches.”
Technical Challenges and Innovative Solutions
Creating Tinman wasn’t simply a matter of aesthetic modifications. The shortened wheelbase required complete reconfiguration of the driveline, including custom driveshafts and relocated suspension mounting points.
“The biggest technical challenge was maintaining the approach and departure angles while ensuring the vehicle’s center of gravity remained manageable,” Matt explained, pointing out the custom suspension geometry. “Shortening the wheelbase improves maneuverability but can make a vehicle dangerously unstable on side slopes.”
To address this, Matt installed a set of remote-reservoir King shocks with custom valving, paired with significantly stiffer springs than a standard FJ would run. The combination provides both remarkable articulation and necessary stability when traversing challenging terrain.
The other major hurdle was power delivery. While the stock 4.0-liter V6 remained largely untouched internally, Matt completely overhauled the intake and exhaust systems to compensate for the vehicle’s altered aerodynamics and increased rolling resistance from the 35-inch Maxxis Razr mud tires.
“We picked up about 15% more torque and about 22 additional horsepower just through breathing modifications and a custom tune,” he noted. “The shorter, lighter vehicle with more power makes for a completely different driving experience than the stock FJ.”
Perhaps most impressive are the drivetrain modifications. Both front and rear differentials received ARB air lockers, with custom-cut Spider gears to handle the more aggressive power delivery. The transfer case underwent similar strengthening, with aftermarket low-range gears providing a crawl ratio that would make a mountain goat jealous.
Breaking the Internet (and Traditionalists’ Hearts)
When photos of the partially completed Tinman first appeared on an Australian 4×4 forum in late 2019, the reaction was swift and polarized. Some hailed it as visionary; others condemned it as sacrilege.
“I stopped reading the comments after a while,” Matt admitted. “Some people were genuinely angry that I’d ‘ruined’ an FJ Cruiser. Others thought it was impossible to maintain structural integrity with those modifications.”
The controversy only intensified when a well-known 4×4 publication shared the images on social media, generating thousands of comments and shares. Overnight, Tinman became both the most admired and most controversial build in Australia’s tight-knit off-road community.
“The project actually stalled for a few months after that. The attention was overwhelming,” Matt revealed. “I started second-guessing myself, wondering if I’d made a massive, expensive mistake.”
That changed during a chance encounter with legendary Australian off-road racer John Hederics at a parts store. After seeing photos of the project, Hederics encouraged Matt to stay the course, offering technical advice on chassis strengthening techniques he’d learned through decades of Outback racing.
“Having someone of his caliber validate the concept gave me the push I needed to finish it,” Matt said. “From that point on, I stopped caring about the critics and focused on building the vehicle I’d envisioned.”
From Workshop to Wilderness
After 18 months of intensive work and approximately $60,000 in parts and materials (not counting thousands of hours of labor), Tinman was finally trail-ready in early 2021. Matt’s testing ground was the notoriously challenging Landcruiser Mountain Park outside Brisbane.
“The first real test day was nerve-wracking,” he recalled. “I’d done all this work, all this planning, but you never truly know how a vehicle will perform until you push it in real conditions.”
Those concerns evaporated within minutes of hitting the trails. The shortened wheelbase allowed Tinman to navigate tight switchbacks that would have other 4x4s performing three-point turns. The chopped roof lowered the center of gravity so dramatically that the vehicle could handle off-camber sections that would tip a stock FJ Cruiser.
“It was one of those rare moments where reality exceeds your expectations,” Matt grinned. “All those sleepless nights, all that second-guessing – suddenly it all made sense.”
Word of Tinman’s capabilities spread quickly through Australia’s 4×4 community. Invitations to group runs and events poured in, with many enthusiasts eager to see the controversial build in action. What many expected to be a compromised show vehicle proved to be an exceptionally capable off-roader.
During the notorious Coffs Harbour 4×4 Challenge, Tinman completed obstacles that stopped modified Land Cruisers and Patrols in their tracks. The combination of aggressive approach angles, reduced wheelbase, and custom suspension geometry allowed Matt to navigate technical rock sections with almost casual ease.
“There’s a specific rock step there that most vehicles need a winch to conquer,” explained veteran 4×4 instructor Mike Sampson, who witnessed Tinman’s performance. “Matt just picked a line and drove up it. Made it look embarrassingly easy. That’s when I realized this wasn’t just a radical-looking build – it’s genuinely exceptional from an engineering standpoint.”
Living With a Legend
Two years and thousands of off-road kilometers later, Matt has refined Tinman further, addressing minor issues that emerged with regular use.
“No project is ever truly finished,” he philosophized as we inspected recent additions including upgraded radius arms and a custom-built rear canopy system. “Each trip reveals something new to improve.”
The vehicle has evolved from weekend warrior to expedition-capable machine. Recent modifications include a complete electrical system overhaul featuring lithium auxiliary batteries and solar charging capabilities, enabling extended trips through remote areas without sacrificing comfort.
“We did the Simpson Desert crossing entirely self-supported last year,” Matt noted proudly. “Eight days completely off-grid with hot showers, cold beers, and all the comforts. The vehicle performed flawlessly.”
Perhaps most surprising is Tinman’s practicality as a daily driver. Despite its radical appearance and purpose-built off-road focus, Matt uses it for his 30-kilometer commute most days.
“Fuel economy is actually better than the stock FJ,” he explained. “The aerodynamics are different but more efficient, and the weight reduction makes a noticeable difference. It’s about 300 kilograms lighter than standard.”
However, daily driving does come with certain challenges – primarily the attention Tinman attracts.
“I can’t fill up with fuel without someone wanting to talk about it,” Matt laughed. “Quick trips to the supermarket turn into impromptu car shows. It’s flattering but sometimes exhausting.”
Influence and Legacy
Tinman’s influence on Australia’s custom 4×4 scene has been profound. At least three similar FJ Cruiser chop projects have begun since Tinman’s completion, with builders citing Matt’s creation as direct inspiration.
“I’m happy to share information with other builders,” Matt said. “This hobby progresses when people push boundaries and then help others do the same.”
The build has also caught the attention of aftermarket manufacturers. ARB, Australia’s largest 4×4 accessory company, used Tinman in a series of promotional photos, showcasing how their products can integrate with even the most radical custom builds.
Perhaps most validating was Toyota Australia’s reaction. Initially skeptical when photos first circulated, representatives from Toyota’s marketing department eventually reached out to Matt, ultimately featuring Tinman in a social media campaign celebrating creative interpretations of their vehicles.
“Having Toyota acknowledge the build was surreal,” Matt admitted. “I half-expected a cease-and-desist letter when it first went viral, not an invitation to display at their corporate events.”
The Future of Custom 4×4 Building
As we concluded our time together, Matt shared his perspective on the future of custom 4×4 building in an age of increasingly complex electronic systems and manufacturer restrictions.
“Modern vehicles present unique challenges for customization,” he acknowledged. “When everything is integrated through central computers, even simple modifications can trigger cascade failures in seemingly unrelated systems.”
Tinman represents perhaps the last generation of vehicles where radical structural modifications remain feasible without specialized manufacturer-level diagnostic equipment. Newer vehicles with integrated safety systems, adaptive suspensions, and interconnected control modules make such dramatic changes increasingly difficult.
“I think we’re entering an era where software modifications will become as important as hardware changes,” Matt predicted. “The builders who understand both mechanical engineering and vehicle electronics will create the next generation of legendary builds.”
As for Tinman’s future, Matt has no plans to sell his creation despite receiving several significant offers, including one that approached six figures.
“This vehicle represents thousands of hours of my life and countless challenges overcome,” he reflected. “The journey of building it has been as rewarding as using the finished product. How do you put a price on that?”
Instead, he continues to evolve the build while documenting the process for others. A detailed build thread now spans over 200 pages on an Australian 4×4 forum, providing invaluable guidance for those attempting similar projects.
“If Tinman inspires others to pursue their vision rather than following the crowd, that’s the best legacy I could hope for,” Matt concluded. “The 4×4 community needs people willing to think differently.”
As the sun set over his workshop and Tinman’s distinctive silhouette cast long shadows across the concrete floor, that legacy seemed secure. In a world of cookie-cutter builds and predictable modifications, Matt Harrison’s chopped FJ Cruiser stands as a testament to personal vision, engineering excellence, and the enduring spirit of Australia’s custom 4×4 culture.
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