About Forged Chassis
Three generations of forging, aimed at one problem
Toyota 4x4s outlive their chassis. We make the replacement mounts, crossmembers, axles and brackets that put them back on the road — engineered and manufactured in Ireland, to a standard beyond the parts they replace.
2019
First moulds engineered
3
Generations in iron
4
Component families
IE
Designed & tooled in Ireland
01 — Origin
It started with parts that did not exist
Seven years ago we began fabricating components for Toyota 4x4s because the ones owners needed were not being made. Rust takes the chassis long before it takes the vehicle, and the choice on the table was a full replacement or a repair nobody trusted.
In 2019 we engineered our own moulds and kept investing from there — tooling, material, process — until we could bring a full range of axle and chassis components to market rather than one-off fabrication.
NS4x4 were our first partners in Europe. The work now is to grow the brand on the same expertise that built it.
02 — Heritage
Three generations of iron forging and metalworking
The knowledge behind a Forged component is older than the company. Die forging, tool design and heat treatment were the family trade before they were our production line, and that inheritance is why we tool our own moulds instead of buying someone else's.
Repair, not replace
Precision-forged solutions that avoid the cost of a whole new chassis.
Built on legacy
Forging expertise carried through three generations of metalworkers.
Innovation driven
Industry-first components for repair problems the market ignored.
03 — Capabilities
What we make
Four component families covering the structural repair of a Toyota 4x4, supplied to owners, workshops and distributors alike.
Chassis mounts
Load-bearing mounts forged to restore the original geometry of a corroded rail.
Crossmembers
Full-width members that return torsional stiffness to the frame.
Axle components
Suspension and axle parts made to the tolerances the assembly was designed around.
Brackets
Steel forgings for the fixing points that fail first on a working vehicle.
04 — Manufacturing
How a part gets made
Tool design
Every component starts as our own tooling. We engineer the moulds in-house, which is what allows us to correct the weaknesses in the part we are replacing.
Die forging
Closed-die forging gives a continuous grain flow through the part — stronger under load and fatigue than a fabricated or cast equivalent.
Material control
Specified steel, consistent batch to batch. The standard of material is half the reason our parts outlast the originals.
Powder coating
Finished to resist the salt and water that took out the part being replaced, so the repair is not a repeat job.
Mass production
Tooled for volume, not one-offs — repeatable parts in quantities distributors and workshops can plan around.
05 — Beyond OEM
A replacement should be better than what failed
The engineering standard and the materials in our axle and chassis components are an advance on the OEM parts they replace. Same fit, longer service life.
Fit
Dimensionally faithful to the original, so it goes on without modification.
Strength
Forged grain structure and specified steel where the original used the cheapest option that passed.
Protection
Powder-coated finish specified for the conditions that caused the failure.
Tradition forged into innovation
Strength you can trust