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For clarification what specifically needed to be filed? The grooves themselves (i.e. making the grooves deeper) or was it the outer diameter of the splines that was too big? Or both? Thanks for your super helpful write-up by the way!

A recent post in the past month I think describing installing the Swayaway torsion bar indicated the splines were a bit to large or else the grooves not deep enough and they filed them before installing. Sounds like you have a similar problem. EDIT: Found the thread -...

Overall FWC dealer's advice not bad. You definitely need leaf springs. All Pro Expedition, OME Dakar with the add a leaf or get a custom pack made by Deaver. Now once you do that you will probably have a rough ride when the camper is off of the truck but given your application I think that's...

Worst that will happen is you go slow up grades. You are on the grade for 10 to 15 minutes and you are enjoying your truck and camper for days and days. I'd skip engine mods to chase a few more HP. Often they don't yield much and start stressing components that were previously happy. I drove...

Lifted Tacoma with a FlipPac or RTT and appropriate off road wheels should be about 15 highway and 10 trail. That's what everyone with a similar configuration gets. Tacomas are gas hogs.

Roughly $6K new. There is a market and AT is filling it with their Habitat which has been around for about one year now. The AT option is a bit higher end materials and construction wise and comes in about 30% more expensive new than the FlipPacs retailed for.

Some people use rivets and some just use screws. Really up to you. I would install at the correct point for the bed to be level with the rear. Usually the torsion bar leaves the bed a little high and you have to pull it down. I'd put something flat along the top of the shell and the bed...

My FlipPac on a 2015 DCSB clears the shark fin but the bed side caps are still on (this is the standard way FRP did installs). It is close though so I wouldn't be surprised if you removed the bed side caps like AT typically did for their installs that you might have an issue with the shark fin...

You mean the tent itself? Or the FRP made separate rain fly? Or the SLO-sail separate rain fly?

Well it would be the same rack for an access cab...

Well until a month or so ago there was no source for a torsion bar anywhere at all. Sway-a-way fortunately just started making them. First batch was made and shipped out in just the past couple of weeks.

There is only one torsion bar design for all Flip-Pac sizes. The lid and tent is identical on every Flip-Pac regardless of the overall shell size. I can't imagine how one could get rocks to hit the bar. It is physically impossible to do with your own wheels of course and if you were following...

Thanks for the awning description Mario!

So I'm guessing from looking at the pictures that on the DCSB version the gas struts and the different lid design make it impossible to mount a Fiamma awning on the side like was often done on the Flip-Pac?

Just to round out this thread, if you want more discussion on the new Sway-A-Way replacement there is discussion along with a description of the design changes from their engineer in this thread: http://www.expeditionportal.com/forum/threads/162134-FLIPPACK-CAMPERS

Thanks so much for this! Yes, very helpful and easy to understand. Glad to hear of the improvements you've made. I'm probably going to order one or two of these by the end of the year just for backup. My first FRP bar lasted less than six months and twenty openings. Who knows how long my...

Woo Hoo! Right now my Flip Pac purchased in spring of 2015 has already had one torsion bar replaced. The current one could of course last 20 years or break the next time I look at my truck funny. I'll certainly be placing an order for a back up in the next month or so. Thanks so much for...

From experience with a FlipPac the tent structure is likely very robust to wind. I've had my FlipPac up in sustained strong desert winds with no issues. At least with the FlipPac the tent noise gets very loud though. And being that the tent is six or seven feet off the ground it does catch...

Got it! Yep you are right for 2nd gen TRD = V6. Cheers!

Actually they don't and it has nothing to do with trim package. All V6 2nd Gen Tacomas have a transponder key regardless of trim package. All I4 2nd Gen Tacomas do not have a transponder key regardless of trim package. Now certain packages may not commonly come with an I4 and thus typically...