Overlanding has seen a surge in popularity over the past few years, a trend bolstered in part by pandemic-driven cabin fever, and then further fueled by the wider availability of high-quality, purpose-built gear for the task. While there’s some overlap between the hardware used to outfit a vehicle for overlanding and that of a traditional off-road build, there are important differences as well. And as Bryan Grigsby, director of Holley’s Off-Road and UTV business unit, points out, those differences fundamentally affect how one should approach the project.

“Think of it as ‘long-range camping,’” he says. “You’re utilizing the capability of the vehicle to access more remote places than you’d be able to reach in an unmodified passenger vehicle, and these treks off the beaten path can span several days at a time.”

Given the inherent need for self-reliance, it can be tempting to over-build an overlanding vehicle in an effort to plan for worst-case scenarios. However, Grigsby says that a more strategic approach will ultimately yield better results and save you money along the way.

“You want to build the vehicle out to your specific needs, so you need to really consider what those needs are. Are you going to be doing shorter overnight treks, or are you planning to take multi-day trips? Those are two different modification paths. If you’re doing overnight trips, you’re not going to need generators, auxiliary fuel tanks, multiple spare tires, and a lot of other gear that you would need if you have to rely on yourself for recovery in the middle of nowhere. All of that has to be taken into account because the more equipment you load onto the vehicle, the more stress you’re putting on its components. So, you want to think about that when you’re starting the project.”

There isn’t a “one size fits all” solution to overlanding vehicle preparation, but taking a realistic assessment of how you’re going to use the vehicle will get you headed in the right direction during the early stages of the project. This, in turn, will help avoid situations where you end up having to spend money twice to replace an ill-advised modification with something else.

With that in mind, Grigsby suggests focusing on these aspects of the vehicle’s capability before you turn your attention to roof tents and LEDs.

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TIRES

It’s no secret that tires play a crucial role in any vehicle’s capability, but selecting the right option is especially important for would-be overlanders.

“Consider where you plan to go on your overlanding trips and the terrain you’ll encounter,” Grigsby says. “If you’re going to be running around in the sand in the Southwest, a mud terrain tire is probably not the best option for you. Mud terrains are designed to dig into the terrain, and if you dig into sand, you’re never going to find the bottom. Conversely, an all-terrain tire likely wouldn’t be the best choice in the Northeast, where the conditions are rockier and slicker. That’s where you’ll want the bite that a mud terrain offers. This is where local overlanding clubs can be a valuable resource: Learn what works and what doesn’t from people in that region who have already done it.”

In terms of sizing, Grigsby says that since most overlanding builds involve raising the vehicle’s ride height in some way, those modifications need to be taken into account when selecting wheels and tires. “Any time you’re lifting the vehicle up, you’re going to want to widen the footprint to some degree for stability.”

Widening the track is particularly important for an overlanding build because it helps counteract some of the handling compromises that come with adding a bunch of equipment to the vehicle.

“We’re putting a significant amount of additional weight up high, so we want to widen the track to balance it out,” he adds.

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SUSPENSION

If you’re stepping up to bigger wheels and tires, you’ll probably need to bring some suspension mods into the mix to avoid clearance issues. But while bigger is often better in the truck and SUV world, Grigsby advises against sky-high lift kits.

“Suspension upgrades are generally required to fit those bigger wheels and tires on the vehicle, so people tend to do these modifications at the same time. Your main goal should be to get the clearance you need without raising the chassis any higher than necessary. The higher the vehicle sits, the higher its center of gravity.”

Although the specifics vary by platform, Grigsby offers two popular scenarios for overlanding suspension upgrades.

“A Jeep Wrangler has a straight axle up front, so regardless of whether you do a two-inch lift or an eight-inch lift, that axle is going to have the same ground clearance. Your mindset should be to get the largest tire on the vehicle that you can, to gain the ground clearance you need, while keeping the suspension height as low as possible for stability. It’s a balance.”

“When we get into vehicles like the new Ford Bronco, which has an independent front suspension, we often see people just doing a static leveling kit, or something along those lines, and that solution tends to work really well for casual overlanding. Later on, as the individual’s modification journey evolves and they take on more involved overlanding trips, it would make sense to upgrade to a better shock with some adjustability.”

He cites ADS Suspension’s Overland Series as an example of hardware that takes the unique characteristics of this type of off-roading into account.

“There’s something of a ‘secret menu’ when it comes to ADS’s product lines – we actually have an overlanding coilover – or a spring and shock package for non-IFS platforms – with spring rates and shock valving that’s tailored to popular platforms like the Toyota 4Runner, Ford Bronco, and Jeep JK. You can even call in, give us your corner weights, and we’ll build a custom Overland Series coilover for your vehicle based on that information.”

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BODY AND CHASSIS PROTECTION

Protecting vital vehicle components is crucial when you’re venturing into remote areas.

“Skid plates should be on every overlander’s radar,” Grigsby says. “And that goes beyond skid plates that protect the oil and transmission pans. Axle skid plates, shock skid plates, control arm skid plates; you want to account for all of the components that might make contact with an obstacle on a trail and leave you stuck if they get damaged.”

But as with the other modifications discussed here, the level of recommended protection is largely dependent on how the vehicle is being used and the terrain it will encounter. “If you’re in the desert, you probably won’t need half-inch-thick skid plates,” he says. “But if you’re running through areas with a lot of rocks, you’ll want protection that’s pretty robust.”

He also recommends a winch bumper with integrated tow hooks as a solid upgrade for virtually any overlanding build, as it allows for self-recovery while also protecting the front end of the vehicle and improving its approach angle. A bumper with tow hooks and a high-clearance design is also recommended for the rear of the vehicle.

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EXHAUST

Grigsby notes that an aftermarket exhaust system can resolve several potential issues simultaneously.

“We’ve added the larger rolling stock, the skid plates, and the bumpers, and that’s all adding weight to the vehicle. And while we have a high-clearance rear bumper now, it won’t do us much good if we’ve got a low-hanging factory exhaust system. Switching to an exhaust designed for off-road applications will not only improve the vehicle’s departure angle, but it can also help regain some power to offset those added pounds.”

He cites Flowmaster’s American Thunder systems as a good option for those seeking a high-clearance exhaust system that won’t rattle your teeth out on the trail.

“You’re looking for a system that doesn’t hang below the bumper line and, in my opinion, something that doesn’t have a super-aggressive tone. Due to the nature of overlanding, you’ll be in the vehicle for extended amounts of time at lower RPMs, and that’s right where aggressive systems tend to resonate. You want an exhaust that’s not fatiguing in that situation.”

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TUNERS

Like a high-clearance exhaust system, a tune can provide several different benefits to an overlanding build. “When you switch to larger wheels and tires, you’re adding a lot of rotating mass, which impacts performance,” Grigsby says. “A tuner like the Diablosport inTune i3 can add horsepower and torque to help compensate for that.”

It’s also worth noting that installing larger wheels and tires will likely cause your factory speedometer to read inaccurately, but the inTune i3 can recalibrate the system for custom tire sizes. This tuner can also improve fuel economy, scan and clear trouble codes, and much more.

Grigsby reiterates that the key to success with an overlanding build is the development of a thoroughly considered plan. “And like any off-road build, you should expect that plan to evolve as you go along. Just be patient, learn, and talk to as many people as you can who are doing this.”

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