Plan is next week, once the wife and kids go visit family. I can't wait! I did a test fit today, I got about 3/4 turn on the steering wheel before contact. The rear looks to clear without issue. Addison, do you recall how long it took you per side? I'm hoping to finish one tub after work. Then the following day the other side. I don't believe it's essential to weld the entire replacement in. I'll just tac weld every inch or so then use seam sealer.
Probably 10 hours total. But that was really taking our time and having a couple beers throughout the process.
It took me about 3 1/2 hours to tub my brother in laws truck. It is best to have someone in the cab with a wet rag watching for fires! I also recommend using at least 16ga as you will cut a fair amount of support out of the corner near the bottom hinge. You most likely will have to trim and plate the body mount as well, some have gotten away without doing this but we did have to on his truck.
Good luck, you will love the 35s!
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I also did the wet rag thing to stop a potential fire. I did not need to trim body mount, but this will also have to with wheel backspacing. We are running the same wheels and spacing so I bet you will be ok, and the BFG's measure slightly smaller than my Toyos.
I won't do the project by myself, I have a welder fabricator buddy who said he'd give me a hand/stand fire watch while I cut and weld. Or jump in if I keep burning through the thin sheet metal. As for material I have some 16g, 1/8, 3/16 and 1/4 plate hanging around. Did you have to trim the interior panels?
I did not have to trim my interior panels at all.
Some people seem amazed how little I trimmed for my BIG Toyo 35's. Keep in mind the caster settings when you run UCA's will greatly increase your clearance. I believe I now sit at about 4 degree of caster (would have to confirm with my last alignment slip), so it is not maxed out. I have had 4 alignments since the TC arms were installed to fine-tune this setting and keep wander to a minimum while allowing the most wheel clearance. My caster when running the factory arms (during the tub procedure) was maxed out at whatever the factory arms allow.
Curious, will you be trimming the radius of your front fender? With UCA's, 35's, and 3.5" BS wheels you will without a question be eating the fender. I tried to keep my OEM flares but the tires eventually decided for me and they were literally ejected.