What are the Most Important Features of an Overland Build?

The overland lifestyle varies widely in the level of participation, from weekend warriors to continent conquerors. Do you even overland, bro? There are lots of opinions on what a ‘true’ overlander is, but when we put our egos aside we can find a couple common threads. The freedom of movement and the enjoyment we get by overcoming obstacles in our path. The Overlanding lifestyle has grown in popularity in recent years, and because of this, there are many aftermarket solutions available for consideration. We’ve set out to explore some of the main features and available solutions to consider for an overland build.

Reliable 4x4 Platform – Your Most Important Choice

First things first, you gotta start with a 4x4 vehicle that’s worth its salt. Do you go with a truck or an SUV? A Toyota or a Jeep? Should it be a used vehicle no longer under the manufacturer’s warranty, or fresh off the assembly line? Wars have been waged over this topic but we feel there are a wide variety of good options, where none of them are wrong. Common choices are the 4Runner & Tacoma, Lexus GX Series, Land Cruiser 80 Series, 6th Gen Bronco, F-150, Wrangler/Gladiator, and on and on. What is important is that it has 4WD and enough power to haul your equipment or overland camper up and across rough terrain. Once you’ve chosen your vehicle, it’s time to begin upfitting.

Upgraded Suspension – Grab a Couple More Inches of Clearance

As with your choice in vehicle platform, your suspension set up has a range of options for performance and price. You should expect to spend $300-$500 or more per shock, depending on what you’ve budgeted for it. Consideration should begin with ground clearance and wheel clearance, particularly at the front end. Gaining another 2-3” of clearance is standard, even with a decent factory height. To allow for larger all terrain tires, the front end should be level with the rear, which comes in the form of a levelling kit or shock kit that includes a levelling spring.

Popular budget options include Bilstein 5100s, Icon, & Eibach 2.0. These all will improve handling and feel both on and off the road. But if you want to spend a little more you can go with options such as King, Fox, and Old Man Emu among others. When you really start getting into suspension you get into upgrading your upper control arms, bushings, uniballs & other components.We just want to touch on the basics, so be sure to do ample research for your specific vehicle, needs, and budget.

Wheels and Tires – Bigger is Better (In Most Cases)

When considering new off-road tires we also need to look at wheel options. Common sizes are 16-17” for most applications, but those running 37” and larger tires often go as large as 19” wheels. Beadlock style wheels are designed to grip the edge of the tire to help keep it in place when it’s been aired-down for off-road travel. When tires are kept at lower air pressures it provides a much smoother ride than fully inflated tires when crawling over large rocks and other obstacles.

When driving off-road, it’s important that you can get up and over obstacles if you can’t drive around them. In addition to your suspension setup, large enough tires are important for clearing large rocks, roots, and the like. You also want to have enough grip to handle mud, sand, and other slippery terrain. At a minimum we recommend 33” tires, but at that point why not go a couple inches larger with 35s if they’ll fit? For most full size trucks you can go as large as 37” tires, and a few of us even go as large as 40” (But that’s really for the hardcore crawler). In any case, your end result should improve your ground clearance and give you the grip you need. There are a lot of brand options to consider, including BF Goodrich, General, Duratrac, Nitto, and many more.

Must-Have Recovery Gear – Redundancy & Rescue

At the core of overlanding is the principle of being self-sufficient and prepared to overcome any obstacle in your path. This is why we spend time (and money) upgrading our rig with better tires & suspension components. It’s why we cut fenders and improve our approach and departure angles… But even with all these upgrades we may find ourselves stuck in the mud, or unable to get up and over an obstacle in our path. If you’re travelling overland in a remote area, you have to be able to save yourself. Here’s the short list on must-have recovery gear:

Spare Tire - At least one tire, but if your setup permits why not have a second spare.

Tire Patch Kit - Save a spare, patch a tire. If the puncture is in the tread area and not the sidewall, it makes sense to patch it and save you spare in case you get another puncture. You can get a new tire(s) once you’re back in civilization.

Bottle Jack or Hi-Lift Style Jack - You’ll need one that can accommodate your lift. Be sure to research and test the jack you pack to ensure it’s the right fit for your vehicle.

Recovery/Traction Boards - These boards come in a pair, and are used to give a surface for your tires to grip when stuck in sand, mud, or snow. They can be used proactively by being placed ahead of your tires when you spot a mud bog or other obstacle you suspect will sink your tires.

Winch Bumper - Whether you’re stuck in mud/sand/snow or can’t quite make it up a steep obstacle, a winch is a capable ally. You’ll want to have one for when your traction boards aren’t quite enough. It’s important to install a winch that can handle your rig with ease. A 12,000lb winch is standard for about any rig.

Pulley Block, Tree Saver, & Shackles - Using a pulley block, or snatch block, can double (single pulley block/tree saver/shackle) or triple (double pulley blocks/tree savers/shackles) the load capability of a winch. It’s also great for redirecting the pull when you can’t line the two up in a straight line. Add a tree saver to the mix to more safely secure your winch cable around a tree trunk or branch minimizing damage to a tree. If you’re rolling solo you don’t want to get caught without a full winch system that includes a pulley block.

Work Gloves - Protect your hands.

Shovel - You may need to dig your tires out of thick mud or sludge before a traction board or winch can help you. Plus, they’re great for digging poop holes. Traction boards can sometimes double for a shovel but they’re not particularly efficient at the task.

** This is by no means a comprehensive list of recovery gear, but meant to illustrate the bare bones essential gear to have as a solo overlander.

Water Storage & Filtration

There are different options for managing drinkable water on long trips, from a 3-stage water purification system to boiling water as you go - or just plain packing enough filtered water to last the whole trip. A good rule of thumb is to have access to at least 1 gallon of water, per person, per day for drinking, cooking, & cleaning. Now on a shorter trip or one where you will have access to refill your water tank(s) you don’t have to worry about filtration systems. However, it’d be good to have a small, portable water filter in case of emergencies or if you get stuck in an area for longer than intended.

Fuel Consumption & Storage

It’s a shameful feeling to face something avoidable like running out of gas. It’s even worse when you’re dozens if not hundreds of miles from the closest gas station. Bring more fuel than you need for your trip. Remember, your gas consumption will be greater when driving off-road versus freeway driving. Fill your tank at the last available gas station before heading off-road. Along with a full tank of gas bring at least one emergency refill tank for unplanned detours. RotopaX tanks are a standard solution for extra fuel storage, and many of our molle storage panels provide provisions for mounting a tank. Or you can use a universal RotopaX mounting plate to securely store the tanks with an efficient use of space. Larger gas jugs are even better if you have the storage space and a way to mount one.

Power System – Dual Battery Setup with Solar Capabilities

You don’t want your fridge, lights, or camp setup draining your starter battery, unless you're looking to spend the night radioing for help. That’s where a dual battery system comes in. By having an auxiliary battery dedicated to your accessories, you can keep your main battery focused on starting your rig.

Add solar panels into the mix, and you’ve got a self-sustaining power source for longer expeditions. Roof-rack mounted or portable solar panels can help recharge your auxiliary battery during the day, making sure your fridge stays cold and your lights stay on even if you’re off-grid for a week. Popular brands like Redarc, Goal Zero, and Renogy offer plug-and-play kits that integrate easily into most builds.

Sleeping Solutions – Roof-Top Tent, Bed Platform, or Interior Conversion

Where you sleep can make or break your trip. A bad night’s rest means a cranky driver the next day. This is not ideal when you’re navigating boulders or finding an overgrown trail. Overlanders generally go one of three routes: a roof-top tent (RTT), a bed platform in the back of a truck or SUV, or a full interior conversion.

RTTs offer a comfy elevated sleeping experience and quick deployment, but they do add weight and wind resistance & noise. Bed platforms keep you inside the vehicle, which is great for stealth camping and harsh weather, while interior conversions (think van-style setups) often include insulation, ventilation, and even a bit of cabinetry for a mini home on wheels. Your choice depends on your vehicle and how much time you plan to spend on the road—but comfort should always be part of the equation.

Storage Organization – Efficient Systems for Gear, Food, and Equipment

We’ve all been there—digging through a mountain of gear just to find your stove or your headlamp. Overlanding is all about efficiency and preparedness, and that starts with good storage solutions. Whether you go with full drawer systems in your trunk, molle panels mounted to the interior or exterior of your rig, or plastic bins strapped down with ratchet straps, having a place for everything (and keeping it there) is essential.

Look for modular storage systems that can make efficient use of your space. Keep essential recovery gear accessible, separate your clean and dirty gear, and label your containers. it might feel excessive until you're fumbling around at 2 AM in the rain looking for a tent stake.

Navigation & Communication Tools – Don’t Rely on Cell Service

It’s not a question of if you’ll lose cell service, it’s when. Overlanders rely on a solid mix of GPS devices, offline mapping apps, and old-school paper maps. Gaia GPS, OnX Offroad, and Garmin Overlander are great for detailed trail info and offline use. Always download your maps before heading out, and don’t forget a good compass and map for backup. Consider a dash mount or center console mounting system for your nav & comm devices.

Communication is just as critical, especially when traveling solo or in remote areas. A GMRS or HAM radio system can help you reach out to your convoy or call for help when cell towers are miles away. For even greater peace of mind, a satellite communicator like the Garmin inReach lets you send messages and SOS signals from anywhere on the globe.

Protection Upgrades – Skid Plates, Rock Sliders, and Bumpers

Once your rig is ready to explore, you’ve got to protect your investment. Off-road trails are full of hazards that can put your oil pan, transmission, or fuel tank in serious jeopardy. Skid plates are your underbody’s armor—they take the hit so your components don’t.

Rock sliders protect your vehicle’s rocker panels from getting crunched on boulders and tree roots, while heavy-duty bumpers (front and rear) offer added defense and the option to mount accessories like winches, lights, and recovery points. These upgrades don’t just add functionality—they add confidence. Because when you’re a hundred miles from the nearest tow truck, your rig’s durability matters more than ever.

You do You

In the end, building the ideal overland rig is less about having the most expensive gear and more about creating a setup that supports your style of adventure. Whether you're heading out for a weekend escape or a months-long expedition, the key is preparation, self-reliance, and adaptability. Each upgrade, from suspension to sleeping quarters, should serve a purpose, enhance capability, and ensure you're ready for whatever lies beyond the pavement. So gear up, plan smart, and remember: the best overland build is the one that gets you there and back safely, and confidently.

Also in News & Information on Off-Road & Overland Vehicles & Builds