The Fit Out
The Goal
We wanted to build an every day drive that could be the perfect two-person long distance off-grid and off-road exploration vehicle.
The criteria:
A range of no less than 1000 kms built into it.
A alternative camping set-up that was easy and fast if we were not staying in a camper trailer.
Sufficient load-carrying ability to enable isolated trips for weeks without supplies.
The build / upgrades
Rear Fitout.
This isn’t a featherweight Instagram fantasy—it’s a solid, dead-serious, built-for-purpose rear fitout in our Chewie, born out of long weekends, countless cups of coffee, and the kind of trial-and-error that only bush mechanics and back shed tinkerers understand.
We built this rig ourselves. No laser-cut kits. No flat-pack fantasies. Just 19mm marine-grade plywood, a box of pocket screws, and a vision that only revealed itself as we went. It’s overbuilt, unapologetically heavy, and strong enough to handle the corrugations of the outback and the chaos of life on the road.
Building Without Blueprints
We had no plan—just parameters.
The fridge sizes dictated the width on the right our Crashpad packing cubes determined the width on the left.
And the need to sit comfortably in the back while waiting out storms or to get some rest gave us the height.
From there, the build took shape like a sculpture—shaped by instinct, adjusted by necessity. We split the floor into two interlocking sections of ply to accommodate the Troopy’s rear width, then built two independent modules—left and right—to allow easier removal and flexibility.
The Dual Fridge Setup
One drawer-style fridge for the everyday grab-and-go.
One top-loading fridge for long-term supplies and cold storage.
We framed everything around these cold warriors—building cabinetry to snugly embrace the draw fridge and some wiggle room on the top for a new fridge in the future as well as leave room to breathe and ventilate. Tie-downs, and cable routing all carved into place to keep things secure when the track turns rough.
The Power
Tucked away, like a secret weapon in the Troopy’s wheel arch void, we installed a 12V lithium power system—enough juice to run the world, or at least your camp.
200Ah Lithium Battery – nestled out of sight but easy to access.
2000W Pure Sine Wave Inverter – ready to power anything from blenders to power tools.
DC-DC and AC Chargers – fed by solar, alternator, or mains when available, making the system as flexible as it is powerful.
This all feeds into a SIMARINE PICO control screen and panel
Water on Tap
We tucked a poly water tank behind the passenger-side module—custom-mounted and strapped to stay put through the worst corrugations. A 12V pump feeds a retractable hose that pulls out with ease and snaps back like a tape measure. It’s simple, and gets the job done —whether that’s rinsing gear, washing up, or plumbing in our shower system. - the water is potable. but we use alternative drink water normaly.
The hose reel is mounted inside the cabinetry, fed from a tee junction off the tank line with an in-line filter and shut-off valves. All tucked away but ready to deploy in seconds. No fuss, No mess.
Tools of the Trade
None of it would’ve been possible without the pocket hole jig—the unsung hero of the fitout. It let us build tight, strong joints without external brackets or exposed screws, making the cabinetry solid as hell and surprisingly clean for something knocked together in a garage.
The finish
We sorted through every sheet of ply at Bunnings like madmen, hunting for A-grade marine ply with clean grain and minimal voids. The finish may not matter to some, but i was looking for specific pieces.
Sealed with a white wash for a clean finish—it’s not a working man’s finish. But its durable, easy to clean, and built to wear the scars of travel with pride.
Suspension and GVM upgrade.
We opted for a 2" Lift Kit using adjustable remote reservoir shocks from FOX Suspension - 2.0 Performance Series IFP
This includes a GVM upgrade to ~3900T
Wheel & Tyres .
ROH Blak Trak steel wheels wrapped in BFGoodrich All-Terrain T/A KO2
Driveline .
We opted for a Air Lockers by ARB - Front and Rear (Twin)
Brakes upgrade.
Terrain Tamer brake rotors, fortified brake pads, replacement standard brake booster with a Dual Diaphragm Brake Booster .
Upgraded raised air intake.
Safari ARMAX™ performance range of Snorkel
Engine performance enhancement.
Custom Tune - Much Needed and hopefully Coming Soon - Something to help move it move it.
Diesel filter upgrade and catch-can from Terrain Tamer.
Heavy Duty Clutch
Any engine performance increase requires upgrading the clutch too, so I fitted a Terrain Tamer fortified clutch.
Camp Lighting
A rear flood lamp by Stedi - Using the Black Edition C4 LED Cube Light (flood) and Black Edition C4 LED Cube Light (diffused)
Air Systems
ARB twin compressor.
Awnings & Shower
Left Side - Alu-Cab 270° Shadow Awning
Right Side - Quick Pitch - Quick-en-Suite Camp Shower
Roof Rack
RL (Gutter Mounted )- Rhino Rack - PIONEER SERIES (Benefit of Heavy duty legs designed for vehicles that have protruding side gutters)
Rear Bar
Kaymar Rear Bar with twin Tyre Swing Arm Racks
