Fuso FG 4x4 Custom Expedition Vehicle Build

jetstreamin

Active member
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.
 

Attachments

  • 37888977_10157545041003362_7004994172608315392_o.jpg
    37888977_10157545041003362_7004994172608315392_o.jpg
    549.4 KB · Views: 540
  • 37912132_10157545040228362_8749277277386178560_o.jpg
    37912132_10157545040228362_8749277277386178560_o.jpg
    423.4 KB · Views: 540
  • 37935741_10157545040433362_2454590379647827968_o.jpg
    37935741_10157545040433362_2454590379647827968_o.jpg
    470.7 KB · Views: 572
  • 37936630_10157545038928362_4531242844341403648_n.jpg
    37936630_10157545038928362_4531242844341403648_n.jpg
    121.6 KB · Views: 560
  • 37987918_10157545038668362_7419028719295004672_o.jpg
    37987918_10157545038668362_7419028719295004672_o.jpg
    444.1 KB · Views: 547

jetstreamin

Active member
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...
 

Attachments

  • IMG_2820.jpg
    IMG_2820.jpg
    93.3 KB · Views: 487

jetstreamin

Active member
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)
 

Attachments

  • 37902927_10157545082683362_4045902065195548672_n.jpg
    37902927_10157545082683362_4045902065195548672_n.jpg
    80.9 KB · Views: 353
  • 37944830_10157545082118362_4758519989521088512_o.jpg
    37944830_10157545082118362_4758519989521088512_o.jpg
    236.3 KB · Views: 369
  • 38025527_10157545083058362_1909355237882200064_n.jpg
    38025527_10157545083058362_1909355237882200064_n.jpg
    97.6 KB · Views: 353

jetstreamin

Active member
Drawings, drawings and more drawings, the design work is progressing ready for manufacture ?
 

Attachments

  • 38405097_10157565353993362_219932755398492160_n.jpg
    38405097_10157565353993362_219932755398492160_n.jpg
    86 KB · Views: 268

jetstreamin

Active member
Our ITEM sample pack and parts catalog arrived today by courier. Looking to use their aluminum extrusion system for the expedition vehicle interior construction of units etc. Very slick, Meccano for big boys!
 

Attachments

  • 38708132_10157578027573362_733029090679848960_n.jpg
    38708132_10157578027573362_733029090679848960_n.jpg
    106.8 KB · Views: 207

Darwin

Explorer
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?
 

jetstreamin

Active member
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.
 

jetstreamin

Active member
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)
 

Attachments

  • 1d5cc9_4fc9aa593b5c47aaaf8e359ca53a0f67~mv2_d_2448_3264_s_4_2.jpg
    1d5cc9_4fc9aa593b5c47aaaf8e359ca53a0f67~mv2_d_2448_3264_s_4_2.jpg
    11.3 KB · Views: 161

Greenbarn

Member
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.
 

jetstreamin

Active member
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!!!
 

jetstreamin

Active member
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/
 

Attachments

  • d7954f9934a81460ca99f809ece071bf_original.jpg
    d7954f9934a81460ca99f809ece071bf_original.jpg
    316.5 KB · Views: 211

Greenbarn

Member
I must be missing something? I found the article and the Kickstarter page but not the purchase page.
Thank you.
 
Last edited:

Christian P.

Expedition Leader
Staff member
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!
 

Forum statistics

Threads
185,527
Messages
2,875,535
Members
224,922
Latest member
Randy Towles
Top