Transforming a Hilux into an Off-Grid Tourer: A Comprehensive Guide

Haydn
Oct 24
3 min read

Updated: Nov 5

From Weekday Workhorse to Off-Grid Tourer

This Hilux was built over multiple stages as parts arrived. The setup is designed for remote touring, long weekends away, and everything in between.

Barwork & Protection on This Hilux Build

Up front, the vehicle features an Offroad Animal Predator Bar, paired with a Stealth Top Hoop and twin 22” LED light bars for serious nighttime visibility. The bar includes rated recovery points and high-lift jack points, making it ready for remote recoveries when the track gets rough.

Along the sides, Offroad Animal rock sliders provide chassis-mounted protection that doubles as a sturdy step. They are strong, practical, and don’t protrude too far—ideal for daily use and tough tracks alike.

PHAT Bars airbox and snorkel installed in a Toyota Hilux SR 2025 for improved airflow and dust sealing. — PHAT Bars airbox and snorkel combo in this Toyota Hilux keeps the intake high, clean and dry

Airflow & Performance Upgrades

Good airflow translates to reliability on long trips. This Hilux is equipped with a Phat Bars 4-inch long entry snorkel and a Phat Bars airbox. The washable filter setup allows for easy maintenance on the road—just clean, re-oil, and continue your journey.

Warnie mentions that it’s “fully sealed, water and dust proof, and sounds pretty sick too.” To cap it off, a Manta 3-inch stainless steel DPF-back exhaust enhances flow and keeps EGTs down under load.

White 2025 Hilux with rooftop tent, canopy, and tray setup for touring. — Built for the long haul - this 2025 Hilux SR is set up as a proper tourer with tray, rooftop tent, canopy and a full off-grid power system.

Canopy & Touring Storage Setup

At the rear, the Boss Aluminium M2 tray and M4 canopy form the backbone of this build. This modular setup provides Thomas with a clean, functional layout for all his touring gear.

Inside the Canopy You’ll Find:

Bushman 85L Upright Fridge: Ample space for food and drinks on extended trips.
Drawer and Table Modules: Ideal for meal prep or tool storage.
Underbody Toolboxes and Central Locking Across Every Door: Convenience and security in one click.
Rear Ladder, Spare Wheel Mount, and Jerry Can Holder: All lockable for peace of mind while travelling.
40L Headboard Water Tank: Gravity-fed for quick access on the road.

Everything is designed for functionality, with the modular Boss system allowing shelves and drawers to be reconfigured as needed.

12V Off-Grid Power Setup Inside This Hilux Build

A proper tourer requires a robust power setup—and this one delivers.

In the canopy sits a full PowerBoss Gen 3 system, featuring:

Redarc RedVision TVMS and BMS1230
Enerdrive 200Ah lithium battery
Redarc 2000W inverter for 240V power
200W solar panel mounted on the tent
LED lighting throughout the canopy

Warnie demonstrated the setup pulling 4 amps of solar in indirect sunlight—plenty to keep the fridge, lights, and charging gear running indefinitely.

Bushwakka ‘The Shack’ rooftop tent mounted to colour-coded Boss Aluminium canopy on Hilux SR5 — Bushwakka Shack rooftop tent sitting open on top of the Boss Aluminium M4 Canopy

Bushwakka Rooftop Tent & 270° Awning

On top, the Bushwakka Shack rooftop tent stands out as one of the smartest touring tents available. Its dual-pivot scissor lift design opens at both ends, providing more headroom and airflow.

Inside, you’ll find LED strip lighting, a 12V rechargeable fan, USB ports, and plenty of storage pockets. The insulated roof shell helps regulate temperature, while the memory foam mattress and shoe bags add comfort and practicality.

Mounted alongside it, the Bushwakka 270° awning offers 12m² of shade and weighs just 25kg. Built-in LED lighting switches between white and amber for bug-free evenings, and it even features a timer function that turns the lights off automatically after a few hours.

Together, they make setting up camp quick, easy, and comfortable—perfect for long weekends or full off-grid adventures.

Lovells suspension from the 3670kg GVM upgrade kit on Toyota HiLux GUN126R Series — business end of the Lovells 3670kg GVM upgrade - compliant, strong, and ready to handle extra weight up front.

Suspension, Wheels & Tyres

Once the canopy, tent, and accessories were added, the factory suspension was no longer sufficient.

We fitted a Lovells 3670kg GVM upgrade, increasing payload capacity by 620kg, thanks to enhanced front and rear axle load ratings. The result? Legal, stable handling even when fully loaded for touring.

To complement this, the Hilux now rides on ROH Lotus 18x9 wheels wrapped in Maxxis Razr AT811s (265/65R18). This combination is strong and dependable, handling everything from sand to gravel without complaint.

ROH Lotus alloy wheels wrapped in Maxxis Razor all-terrain tyres on a white Hilux. — ROH Lotus wheels paired with Maxxis Razors give this Hilux grip off-road and style on-road

Final Thoughts

As Warnie put it, “Does it beat a 79 Series for touring? I think it does.”

With a canopy system built for long-distance travel, an off-grid power setup, and all the essentials for comfort and safety, this Hilux tourer build is ready to tackle Australia’s toughest touring routes.