XTR601/602/603
7t+ GVM, Portal Axle, Full Air Ride, VDJ79/FJA300 Series Landcruiser Motorhomes
These vehicles were developed consecutively for 3 separate clients. Similar to XTR009, this required overseeing the entire design and build, including extensive chassis work, suspension, driveline, storage and habitat system development. These builds incorporated a 6x6 drive system with parts from 6x6 Australia which we deemed to be the most suitable due to its load sharing capabilities, air suspension compatible design, and unique 'power divider' packaging. These projects also presented similar challenges with the design of multiple congruent multifaceted systems with stringent constraints.
The build incorporated numerous bespoke engineering solutions, including:
Rear chassis replacement and 7t GVM upgrade and 6x6 drive and system
Full air-ride suspension conversion using rolling-sleeve airbags
Development of a unique heavy-duty electric rear sway bar remote disconnect system
Custom portal gearboxes with integrated CTIS routing, modified to accept Landcruiser hubs and suitable brake system
Fully integrated Central Tyre Inflation System with in-cab controls
Vacuum-infused fiberglass habitat/pod, including all moulds, tooling, and composite components developed and manufactured in-house
Extensive electrical systems, including automated steps and electric roof actuation
Up to: 1320Ah LiFePO₄ battery system, 1142W solar array, 200A sealed alternator, and 3,000W pure-sine inverter
Over 360L fuel and 343L water capacity
The project required coordination across chassis and suspension design, subframes and tanks, camper design, custom tooling, composite manufacturing, electrical systems, procurement, and final assembly, as well as several related accessory development projects.
XTR603 presented a whole new set of challeneges. It was based on a brand new platform, the 300 series landcruiser GR Sport, so many challengers arose, both expected and unexpected. These included:
Wagon/SUV to Single Cab Ute/Cab Chassis Conversion
Coil over strut air suspension strut development
CAN system integration for a plethora of factory systems
e-KDSS integration including our own electronic rear swaybar disconnects
Complex chassis shape and fabrication techniques
Factory electronic parking brake integration
Additional 300kg GVM upgrade due to larger tare weight
Factory stereo and infotainment system retainment
Despite significant supply-chain challenges, and unexpected design integration challenges, I successfully led the project through to completion and delivery to the clients.
