Fuso FG 4x4 Custom Expedition Vehicle Build

#1
Hi All

Wanted to share the progress as it unfolds on our Fuso FG 4x4 Expedition vehicle build. I will posts updates here as they happen...

I will start by saying getting hold of one of these trucks in Canada was a small nightmare and we ended up flying from Ontario to Red Dear for just that ;o)

First stop after purchasing the truck chassis from Red Dear was in Canmore where i met up with Tony and Australian who runs Fuso Offroad (see https://www.fusooffroad.com)- he sprang into action to remove the flat deck from the chassis as this is not needed for the build - this will be replaced with an articulated off road sub frame and Isolation pads between frame and truck. Next came the winch mount and front bumper and the new wheels and tires - really starting to shape up now. For all those trucker friends of mine that have driven a bare truck chassis you know, it is no its no picnic!! Rough to say the least and thank god my other half is a Chiropractor to put my spine back together lol! Australia is the only place to get the parts for this project, they are so far into this and are for sure the leaders in the market for Expedition Vehicles.
 

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#2
And the adventure continues......Just finished a 1000km drive from Red Dear Alberta to International Truck Body in Vancouver across the Rocky Mountains, just breathtaking! Why??? To deliver our 4x4 overlander chassis which we won’t see now for another 3 months and when we fly back to collect it should look something like this!!! Time to explore further, adventure more and let the custom build begin to breath life into the Expedition Vehicle!

This is where we are heading to in terms of our design...
 

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#3
Next meeting was with Andreas from Total Composites ( See: http://totalcomposites.com) , a German company that will be supplying all of the laser cut composite panels and working in collaboration with ITB on the build. Another great guy and a real expert in his field with years of experience, we went through the structural element and reviewed by design drawings for the project ensuring we had everything in the right place! ;o)
 

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#6
Keep posting tons of pictures. I would like to see how the interior turns out with the aluminum extrusions it seems like a good way to go. Are you planing on just gluing them to the inside of the camper box?
 
#7
Keep posting tons of pictures. I would like to see how the interior turns out with the aluminum extrusions it seems like a good way to go. Are you planning on just gluing them to the inside of the camper box?
For sure Darwin, things will be fairly quiet on this thread until the end of November as that is when we fly back out to BC from Ontario to pick up our expedition vehicle, up until that point it is being built but they are going to send pics of the process i will be able to add here.

Will be a long challenging drive over the Rockies in November but if this vehicle cant do it nothing can!!

For sure on the gluing, as we have ordered a number of tubes of bonding agent from Total Composites for just that. Other than the raised bed and seating there is not much structural load on the internal side and both of those will be supported by vertical supports.
 
#8
Just flew back from Arizona and visited https://www.ternoverland.com/ these are the guys supplying our windows, entry door, cargo hatches and roof hatch. Very well engineered products and i highly recommend them. Had a great demo of all of their products and can't wait to see them in the rig. Incidentally, Overland Journal is right opposite their location and was able to meet the team there ;o)
 

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#9
Wow, we seem to be on parallel journeys but I am tight budget. I bought a 2010 FG in Edmonton on June and drove the bare chassis back to Vancouver Island. I am just organizing the build for a “articulated” flat deck. We plan to mound a flat deck and a removable camper. I have started a few threads in Japanese Heavy Truck section about the process. I look forward to watching your build.
 
#10
Wow, we seem to be on parallel journeys but I am tight budget. I bought a 2010 FG in Edmonton on June and drove the bare chassis back to Vancouver Island. I am just organizing the build for a “articulated” flat deck. We plan to mound a flat deck and a removable camper. I have started a few threads in Japanese Heavy Truck section about the process. I look forward to watching your build.
Ha small world!!! nice one, if we can share ideas it would be great!!!
 
#11
Wanted to share this post from this site as the book is now available in the English language and we purchased a copy - essentially what we are using as our guide to building our rig and I have to say the detail is awesome! I love the way he shares his mistakes and multiple ways to tackle each step of the project. see: https://expeditionportal.com/how-to-build-your-own-expedition-camper/
 

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Christian P.

Expedition Leader
Staff member
#13
Just flew back from Arizona and visited https://www.ternoverland.com/ these are the guys supplying our windows, entry door, cargo hatches and roof hatch. Very well engineered products and i highly recommend them. Had a great demo of all of their products and can't wait to see them in the rig. Incidentally, Overland Journal is right opposite their location and was able to meet the team there ;o)
Very interesting build! I am glad you got to stop by the office!
 
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