Building a custom 4x4 on a budget

“You have all the gear and no idea!” he shouted as I kept digging out the sand from around the wheels.

He was right. I’d gone down on to the beach in the late afternoon to get some sunset pics and video with a mate’s new LC200 and high-end off-road caravan. I’d let the tyres down, but not far enough and was struggling to get the six-tonne combined mass back up the beach access ramp. I had blocked the only access track and the locals were (understandably) very upset with me.

In an era of $150K fully-kitted LC79s towing $150K-plus off-road caravans, it was a stark reminder of the need for us to get ‘back to basics’ and ‘keep it simple stupid’ – or in my case look really stupid! After all, isn’t the whole point of adventure to leave all the stuff and worries behind and get back to nature and things that matter, like family and fun?

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Don’t be fooled – you don’t need to gouge your super or mortgage your home to have the ‘perfect touring set-up’. And, with lead times long in to 2022 on new vehicles, camper trailers and caravans, it’s time to make the most of what you already have. Far better to go now and enjoy the outdoors than spend the next decade paying off some shiny new toy.

So, I dropped home my mate’s rig (most embarrassed) and apologised for not giving him any decent Insta pics. Then I went home to look at my own kit through a very different lens.

THE VEHICLE

A genuine one-owner vehicle, we’ve owned the 2004 120 Prado since new. It’s only done 260,000km in 17 years and, as like most Prados, it’s been a ‘mum’s taxi’ for our family of six and driven mostly within a 10km radius of home.

It’s a very reliable 3.0L turbo-diesel coupled with a five-speed manual transmission. I’ve quietly done it up as time and funds have allowed and put together a very competent off-roader.

The ARB deluxe winch bar, side-steps, Safari snorkel, under-bonnet air compressor, dual-battery system and IPF driving lights were all fitted as new. It has an ARB two-inch lift with the Old Man Emu shocks upgraded to OME Nitrochargers back in 2012.

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A few years ago, I replaced the 40-channel UHF with a new GME TX3350 remote handset and upgraded the smart solenoid power with a new 25amp BCDC Redarc smart charging unit, complete with solar input. Navigation aids include a Hema HX-1 Navigator and mounted iPad mini running a suite of map and campsite apps. An ARB TPMS keeps my tyre pressures in check and a Redarc TowPro brake controller helps with safe outback towing.

I need to charge a lot of camera and computer gear, so I mounted a Redarc 1500W pure sine wave inverter under the front passenger seat. I also ran a heavy-duty 12V cable to the rear cargo area to keep the 60L ARB fridge-freezer running direct from the auxiliary battery, and an even thicker cable to feed the trailer via a rear-mounted Anderson plug. The engine had a 15 per cent power upgrade thanks to a Tunit chip.

Next, I swapped the Toyota roof rack for a Rhino platform (1930 x 1240mm) with shovel holder and mounted black MaxTrax. A matte-black bonnet wrap and 17x9-inch Mayhem Rampage wheels shod with my favourite Cooper ST Maxx tyres (265/70/R17) rounded out the tough, black-on-silver look.

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The Prado had done a bit of beach work, so the underside needed some TLC. I replaced the rusted and beaten bash plates with a set of ARB underbody protection and swapped the original tow bar for a Hayman Reese 2.5T rated one, as the hitch sleeve and mounting brackets were looking ‘pretty ordinary’ and didn’t look like they’d survive the next recovery.

The front end needed a bit of work, as the steering had been wandering a lot in recent times. It took the best part of a day to replace the steering-rack bushes and sway-bar links, with much of that time spent removing the original rusted bushes. The final touch was a pair of Airbag Man airbags in the rear to help carry the load when towing.

THE TRAILER

The trailer needed a heap of work! It’s a simple but strong 7x4-foot high-side, off-road box trailer that I bought 15 years ago. I’d used it for landscaping and carting building material when we renovated our 1926 Queenslander. It had a ladder rack for loading timber (or canoes), zinc-plated floor, spare-tyre carrier, tonneau cover and front-mounted toolbox. A set of second-hand GU Patrol alloys and 285/75R17 Cooper STT tyres gave it a stack of ground clearance and tougher stance.

Like the Prado, the surface rust had set in, so I lifted the front drawbar and wire-brushed the underside and then coated the whole trailer with Penetrol. This halted the corrosion and gave it a protective patina finish. It was messy work, but will double its useful life. The toolbox mounting bracket had rusted through the front box section, so it was cut out and replaced and a new one mounted up front. Lastly, I welded a tow hitch to the rear cross-member to carry a family of mountain bikes.

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The toolbox houses a portable battery pack (Thumper) with charge input via an Anderson plug. With a portable solar blanket, this keeps the fridge and lights running for a longer stay. My camp cooking kit is stored in a large space case and fits snugly inside the rear of the trailer, with the open lid locking perfectly against the ladder rack. The tailgate serves as the kitchen bench, with removable chains holding it flat. A 4.5kg gas bottle is fitted nearby for the dual gas stove or Weber Q. The 40L of fresh water is stored in two side-mounted jerry can holders.

I mounted a second-hand James Baroud rooftop tent to the ladder racks with two linking parallel bars. It’s simply secured by four underside U-bolts, making it easy to mount or remove in less than five minutes. The rooftop tent is perfect for my wife and me, and I have two quick set-up swags and a two-person dome tent depending on how many of our four kids come along. A Supa Peg 180o side awning provides ample shade and shelter.

TEST RUNS AND DIY

An overnight camp at nearby Gordon Country gave me a chance to test the new camping set-up, followed soon after by a week-long trip to Fraser Island (K’gari). The missus and boys approved as we were set up at Gordon Country with the campfire started, in under 20 minutes, leaving plenty of time to explore with our new puppy. The lightweight trailer made for easy towing along the beach and inland tracks at Fraser. The Prado found it easy too – it’s a tonne lighter than a fully-loaded LC79 so handles the soft sand with ease.

For two of the four nights, I explored the remote northern and western sides with just the vehicle and swags. Here I found a few like-minded adventurers who had solved some common problems with simplicity and style. Take Charlie for instance, who had solo sailed to Fraser’s west coast and set up camp on the beach for a few days. He’d made himself a self-levelling ‘stable table’ to hold his food and drinks steady on a rocking boat or a swaying branch. Or Dave who had baulked at the cost of $1200 for a slide-out drawer so built his own complete with custom compartments and a fold-out kitchen bench – all for under $200.

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They say necessity is the mother of all invention, but I think it just takes a bit of common sense and not a whole lot of cash. I set out to make the most of what I already had and focussed on keeping it purposeful, lightweight, simple and modular. This means less stress on the car and trailer and keeps my kit fully-adaptable for long, short, solo or family adventures. Plus, I can still use the Prado to take the kids to school or do a dump run with the trailer.

You can easily find a similar mid-size 4WD or ute for around $15K and a quality off-road trailer for under $5K. All my upgrades will have cost me $12,500 across 17 years. So, whether you use a vehicle you own or one you buy tomorrow, you can easily have a capable and versatile 4x4 adventure rig for less than $35K.

UPGRADE LIST

ARB OME suspension
ARB Deluxe winch bar
Smittybilt X2O 10,000lb winch w/ synthetic rope and remote control
IPF Extreme HID driving lights
ARB mounted air compressor
ARB underbody protection and side-steps
Hayman Reese 2.5T tow bar
Redarc BCDC 1225D three-stage battery charger
Redarc Tow-Pro brake controller
Rhino-Rack 1930 x 1240mm platform rack w/ shovel and MaxTrax holders
Tunit performance chip
Hema HX-1 GPS and iPad mini
ARB Tyre Pressure Monitoring system
ARB recovery kit
Airbag Man rear airbag kit
James Baroud Evasion Evo rooftop tent