Okay, so I’ve been obsessed with the idea of turning a Toyota Hilux into a proper SUV. Not just slapping a camper shell on the back, but really making it a comfortable, enclosed space. Here’s how I went about it, and let me tell you, it was a journey!
Getting Started
First things first, I needed a Hilux. I managed to find a used one in decent condition – a bit rough around the edges, but with a solid engine and chassis. That’s the important part, right?
I spent days just staring at it, sketching ideas on napkins, and watching countless YouTube videos of other people’s builds. I knew I didn’t want some flimsy fiberglass shell. This needed to be strong and feel like a real extension of the truck.
The Build Process
Tear Down: I began by taking away the truck bed, which was pretty heavy.
Framing It Out: This was the tricky part. I decided to go with a steel frame, welded directly to the Hilux’s chassis. I’m no professional welder, but I’ve dabbled enough to feel comfortable. I used square tubing, and lots of it, to create the basic shape of the SUV extension. It was slow going, making sure everything was level and square. I got to the step of measuring, cutting, welding, measuring again, grinding down mistakes, and starting over a few times.
Sheeting the Exterior: Once the frame was solid, I had to figure how to wrap up the exterior of my vehicle. I had to decide between aluminum or more steel, and in the end I decide that I should just keep going with steel sheets. More welding! This was even more time-consuming, getting the curves right and making sure everything was watertight. I used a ton of clamps and magnets to hold things in place while I tacked it all together.
Windows and Doors: I salvaged some windows from an old van at a junkyard, which saved me a ton of money. Cutting the holes for them in the steel was nerve-wracking, but I managed. For the rear door, I basically built a custom frame and hinged it like a regular SUV tailgate.
The Interior
The inside was a whole other project. I started by insulating the heck out of it with spray foam and sound deadening material. Then came the fun part: building out the interior.
- Flooring: I used some marine-grade plywood, covered with durable carpet.
- Seating: I found some used SUV seats that fit perfectly. Bolted those suckers right to the floor.
- Storage: I built some custom cabinets and storage compartments, because you can never have too much storage.
- Finishing Touches: I added some LED lighting, a headliner, and even a small sound system.
The Final Result
It’s not perfect, far from it. There are some rough edges, and the welds aren’t exactly pretty, but it’s mine. It’s a real, honest-to-goodness Toyota Hilux SUV, built with my own two hands. And that’s a pretty awesome feeling. I can now drive around in my hand built, custom vehicle.
