Fully Kitted Toyota Hilux Build for Touring

Haydn
19 hours ago
4 min read

When most people think touring, they think LandCruiser. But this Hilux build shows just how capable a properly set-up ute can be. Warnie from BAW Automotive takes us through the full conversion, turning Thomas’s Hilux into a reliable off-grid tourer that’s as practical as it is tough.

From weekday workhorse to off-grid tourer - this Hilux build proves you don’t need a 70 Series to travel Australia.

Built over multiple stages as parts arrived, this setup was designed for remote touring, long weekends away, and everything in between.

BARWORK & PROTECTION ON THIS HILUX BUILD

Up front is an Offroad Animal Predator Bar paired with a Stealth Top Hoop and twin 22” LED light bars for serious night-time 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 offer chassis-mounted protection that doubles as a solid step. They’re strong, practical, and don’t stick out too far - perfect 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 means good reliability on long trips. This Hilux runs a Phat Bars 4-inch long entry snorkel paired with a Phat Bars airbox. The washable filter setup means easy maintenance on the road - just clean, re-oil, and go again.

Warnie notes it’s “fully sealed, water and dust proof, and sounds pretty sick too.”

To finish it off, a Manta 3-inch stainless steel DPF-back exhaust improves 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

Out back, the Boss Aluminium M2 tray and M4 canopy form the backbone of this build. The modular setup gives Thomas a clean, functional layout for touring gear.

Inside the canopy you’ll find:

Bushman 85L Upright Fridge: enough space for food and drinks on extended trips.
Drawer and table modules: perfect 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 when travelling.
40L headboard water tank: gravity-fed for quick access on the road.

Everything’s designed around function, with the modular Boss system allowing shelves and drawers to be reconfigured down the line.

12V OFF-GRID POWER SETUP INSIDE THIS HILUX BUILD

A proper tourer needs a proper 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 showed the setup pulling 4 amps of solar in in-direct sun - 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 sits the Bushwakka Shack rooftop tent - one of the smartest touring tents around. Its dual-pivot scissor lift design opens at both ends, giving 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 provides 12m² of shade and weighs just 25kg. Built-in LED lighting switches between white and amber for bug-free evenings, and it even has 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 went on, the factory suspension wasn’t going to cut it.

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

To match, the Hilux now rides on ROH Lotus 18x9 wheels wrapped in Maxxis Razr AT811s (265/65R18). It’s a strong, dependable combo that handles 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.