XTR009
6.3t GVM, Portal Axle, Full Air Ride, VDJ79 Landcruiser Motorhome
This was my largest and proudest project to date, requiring me to oversee the vehicle from initial customer consultation and concept development through CAD design, tooling, procurement, manufacturing, and final assembly. The project involved developing complex engineering solutions across multiple integrated systems, often addressing challenging packaging constraints while maintaining performance and compliance with stringent ADR requirements.
The vehicle was commissioned by a repeat customer and meticulous collector to commemorate the final V8 diesel Land Cruiser. The build incorporated numerous bespoke engineering solutions, including:
Rear chassis replacement and 6.3t GVM upgrade, with associated payload and suspension modifications
Full air-ride suspension conversion using rolling-sleeve airbags
Design and development of a new radius-arm rear suspension system and heavy-duty rear sway bar
Custom portal gearboxes with integrated CTIS routing, paired with a purpose-designed rear axle housing
Fully integrated CTIS with in-cab controls, redundancy systems, and automated functions
Design and testing of SAE J2530-compliant 17" forged alloy wheels
Big-brake conversion with hydraulic power-assist booster
6-speed automatic transmission conversion
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
640Ah LiFePO₄ battery system, 580W solar array, 200A sealed alternator, and 3,000W pure-sine inverter
275L 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.
Despite significant supply-chain challenges, late-stage customer design changes, and rework required on non-conforming outsourced components, I successfully led the project through to completion and delivery to the client in WA. The vehicle was subsequently registered and has proven itself both on and off road, with only minor technical issues that were resolved remotely. The client was highly satisfied with the final build and its overall quality.
