35s, 37s or 40s? Building a Tacoma on 74W Portals
The first question in an off-road build should be how you plan to use the truck. Tire size, suspension, wheels, and supporting modifications all follow from that answer.
In our latest video, Quinn and Jason sit down in Big Bear to discuss that process through Jason’s second-generation Toyota Tacoma. Having run 35s, 37s, 38s, and 40s on portals, Jason has experienced what each step adds—and what it asks of the rest of the truck.
The conversation focuses on 2nd and 3rd generation Tacomas, with lessons for anyone planning a portal build.
A rock crawler you can drive home
Jason started with a dedicated solid-axle Toyota crawler on 40s. It had dual transfer cases and plenty of capability, but it only carried one passenger and needed a trailer to reach the trail.
His Tacoma had a different job to do. He wanted room for family, friends, and camping gear, along with the ability to drive to a difficult trail, wheel it, and drive home with the air conditioning on.
That goal ultimately led him to 40s. But the stages along the way helped him identify the setup he would recommend to most owners.
35s: A straightforward starting point
Jason’s initial setup paired 74Weld portals with stock TRD Off-Road suspension, 35-inch mud-terrain tires, and +35 offset Method wheels.
Fitting the tires still required clearance work around the pinch weld, cab mount, and surrounding plastics. While he initially made the setup work with more limited modifications, he explains that a cab mount relocation would have been a better use of his time.
The lesson is simple: portals provide clearance, but tire fitment still depends on the actual tire, wheel offset, and available space throughout suspension travel.
37s: His favorite all-around setup
When Jason moved to 37s, he committed to a cab mount relocation and additional trimming. An aftermarket bumper also helped provide clearance at the front.
With properly tuned replacement shocks, that configuration became his favorite balance of trail capability and everyday drivability.
Quinn and Jason also recall their Rubicon trip, where portal-equipped trucks on 37s completed the same obstacles as trucks on larger tires. The smaller tires proved capable on difficult lines while keeping the overall build more manageable.
For Jason, that was the stage he would point most people toward when asked how to build a well-rounded Tacoma.
38s and 40s: More capability, more commitment
As Jason moved up in tire size, the supporting work grew.
They discuss tubbing for additional clearance and using a pivot kit to move the front suspension forward, reducing interference near the firewall. Just as important is checking the complete range of movement: full compression, full droop, and steering lock in both directions.
A tire that clears while the truck is parked may contact the body when the suspension compresses on the trail.
Tire construction also matters. Jason explains that the weight difference between the specific 38- and 40-inch mud-terrain setups he compared was small enough to influence his decision to move to 40s. That comparison was specific to those tires; diameter alone doesn’t tell you how heavy a wheel-and-tire package will be.
Weight changes how the truck works
Larger, heavier tires affect more than clearance. Quinn and Jason discuss the demands they place on suspension, braking, and steering, especially with camping gear and other cargo aboard.
Jason’s 40s work exceptionally well for his priorities in the rocks. For faster terrain, he says he would choose a lighter, narrower tire with a more compliant sidewall.
That’s why choosing a tire involves more than deciding on a number. Its weight, width, tread, and construction all influence how the truck drives.
Choose wheels for the portal setup
Portals also change the wheel-offset conversation. On the Toyota platform the portals add 3.5" per side, 7" to your overall width. This is an important factor to compensate, or account for, when you're building your rig.
Quinn explains why the familiar approach of choosing a zero-offset wheel for a conventional Tacoma build doesn’t automatically carry over to a portal-equipped truck. Positive-offset wheels are an important part of putting the package together correctly.
The right wheel should be selected alongside the portals and tires, with fitment confirmed for the combination.
Build toward your own goal
Jason achieved what he set out to do. His Tacoma can carry people and gear to the trail, handle difficult rock terrain, and make the drive home without a trailer.
The 40s suit that goal. His experience on 37s also shows how capable a simpler portal build can be.
Before choosing your setup, think about the terrain you actually drive, how much road time the truck sees, what you carry, and how much modification you want to take on. Those answers will help you build a truck you enjoy using.
Watch the full conversation: 35s, 37s or 40s? Building a Tacoma on 74W Portals
Planning a portal build? Visit 74Weld or reach to info@74weld.com and tell us about your vehicle, target tire size, and intended use.
Performance without compromise.
