2005 Nissan Frontier 4WD - BTF Fabrication - Off Road Nissan Trucks

2005 Nissan Frontier 4Wd Right Side View

It’s not often that we run into a uniquely-built Nissan Frontier. Frankly, Nissan didn’t do the most stellar job at creating a truck easily supported by the aftermarket. The OEM front suspension design doesn’t leave a lot of room to work with, and in our world, when it’s tough to make a front kit, companies often don’t want to tackle the rear.

After completing his time with the military in Iraq, Gil Green decided he wanted more out of his ’05 Frontier. He loved his truck when it was still running simple bolt-on products, but was seeking that next level all trucks might have hidden inside. Passionate about off-road and committed to finding the right builder, Gil discovered BTF Fabrication out of Rancho Cucamonga, California.

Over the following year, while Gil was searching for a place to live between California and Texas, BTF worked on creating a unique truck that would not only fulfill Gil’s dirty desires but also leave onlookers gazing and wondering more. With the truck now ready for action, Gil is still living out of a P.O. box and sleeping where he can, but he has a badass truck. That shows he’s got the right priorities. OR

Much of the truck’s OEM frame is still intact. Where it is not, BTF used various tough materials to make it better. The rearmost section of the frame has been boxed and modified to clear the new suspension using 3/16-inch steel. The ’cage throughout the truck is a mixture of 1.75- and 2.0-inch, 0.120-wall DOM steel tube. This combination is MIG-welded throughout and should provide a more than sufficient platform. At night, a lineup of eight 35-watt Kragen HID lamps showers brightness in front of Gil.
Much of the truck’s OEM frame is still intact. Where it is not, BTF used various tough mat
BTF built the truck with racing abuse in mind. If you have any doubt, just look at the rear bumper. If anyone should decide to creep up and give Gil a little love tap, he will be just fine. Two full-size spare tires fit side by side atop the rear ’cage design with a moving tire guard keeping them firmly in place.
BTF built the truck with racing abuse in mind. If you have any doubt, just look at the rea
The 35-inch Nitto Trail Grappler M/T tires tuck nicely into the rear fiberglass. BTR 17x8 beadlock wheels keep the tires locked on at any tire pressure.
The 35-inch Nitto Trail Grappler M/T tires tuck nicely into the rear fiberglass. BTR 17x8

Specs
Vehicle: ’05 Nissan Frontier 4WD
Owner: Gil Green
Chassis: BTF design, DOM tubing
Engine: V-6, 4.0L, K&N intake
Drivetrain: Ford Econoline 9-inch, custom driveshaft, 4.56 gears, Detroit locker, Dutchman axles
Suspension: BTF front long-travel, King shocks, BTF three-link rear with mezzanine trailing arms, Warn hubs
Steering: Stock
Brakes: Wilwood Superlite and Dynalite calipers and rotors
Tires/wheels: 35-inch Nitto Trail Grappler M/T, 17x8 BTR beadlock wheels
Interior: Custom BTF rollcage, Lowrance GPS, GoPro HD camera, PCI intercom, PRP seats, Crow belts
Other Parts: Kragen HID lights, Optima Yellow Top batteries, RCI fuel cell

This is why we called this truck one of a kind. Sure, you have seen a three-link suspension with mezzanine arms before, but how many have you seen on a Frontier? The mezzanine arms are used to gain more wheel travel from a shorter length shock. Considering the small bed space on the Frontier, typical trailing arms would properly put the upper shock mounts in the back seat area. Gil wanted to get away from leaf springs and still be able to comfortably fit four guys in the truck; this was BTF’s solution. The rear now provides 22 inches of wheel travel using King 2.5x12 coilovers, 2.5x14 triple bypass shocks and 2.0x4 hydraulic air bumps. The rear of the truck was lifted approximately 2 inches.
This is why we called this truck one of a kind. Sure, you have seen a three-link suspensio
Not only do the mezzanine arms relocate shock placement, they also act as sway-bar endlinks. They pivot off Warn Dana 44 locking hubs and can be engaged or disengaged simply by locking or unlocking the hubs. A pair of Optima Yellow Top batteries have been relocated to the rear.
Not only do the mezzanine arms relocate shock placement, they also act as sway-bar endlink
Getting under the truck reveals the three-link BTF design connected to 9-inch Ford rear end out of an ’82 Econoline Van. The rear is stuffed with 4.56:1 ratio gears and a stout Detroit locker. Driveshaft Specialist of Covina, California, built a new driveshaft that would allow more movement with the new suspension. Brakes have also received a major upgrade to Wilwood Superlite (front) and Dynalite (rear) calipers and rotors.
Getting under the truck reveals the three-link BTF design connected to 9-inch Ford rear en

The cabin was built to withstand hard impacts or rollovers. Gil added a Lowrance GPS for guidance and a GoPro HD camera mounted to the V-bar capturing his driving prowess in all its glory. Four PRP race seats are mounted to the chassis and Crow five-point belts secure each passenger in place. A PCI Race Radios four-way intercom aids communication.
The cabin was built to withstand hard impacts or rollovers. Gil added a Lowrance GPS for g
About the only place Gil didn’t upgrade his truck was under the hood. He did add a K&N intake that still clears under the chassis design. The main crossbar is removable should the engine need to be pulled. BTF noted that they are not responsible for the wiring found on the truck. That would be the handiwork of Gil himself.
About the only place Gil didn’t upgrade his truck was under the hood. He did add a K&N int
A pneumatic actuator powers the roof-top light rack allowing it to swing forward when not in use.
A pneumatic actuator powers the roof-top light rack allowing it to swing forward when not

Perry Fab N’ Fiber provided its complete front fiberglass clip and bedsides to the project. The much wider front clip was needed considering the 85-inch front track width. Yes, those are Nissan Titan headlights. The fiberglass was perfectly color-matched by L&G Enterprises of San Dimas, California.
Perry Fab N’ Fiber provided its complete front fiberglass clip and bedsides to the project
An RCI 32-gallon fuel cell sits comfortably under the spare tires. The stock fuel cap is still being used.
An RCI 32-gallon fuel cell sits comfortably under the spare tires. The stock fuel cap is s
While most of this truck was custom-built, you can purchase this BTF Frontier 4WD Long-Travel kit. The kit is designed to run King 2.5x10 coilovers and 2.0x4 hydraulic airbumps. It raises the front end by 3 inches and provide 16 inches of wheel travel. Front axles were not in the truck for our photo shoot, but this is a 4WD suspension. This kit is bolt-on save for shock mounts. It uses Nissan Titan hubs and is 4.5 inches wider per side on the Frontier. These same arms will also fit the Titan, but will only increase track width 1.5 inches wider per side.
While most of this truck was custom-built, you can purchase this BTF Frontier 4WD Long-Tra