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Old 02-16-2019, 09:23 PM   #1 (permalink)
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NEVER QUIT Overland's Isuzu NPR Build & 4WD Conversion

Several weeks ago, Matt at Angry Iron Metalworks in Georgia, was contacted by NEVER QUIT Overland, to explore the possibility of getting a 2019 Isuzu NPR crew cab, converted to 4WD.

After seeing and driving Matt’s newly completed 4x4 conversion using a 2015 NPR crew cab, (see link below to the truck we drove) we were blown away by the fit, finish and craftsmanship, as well as how well the truck drove, even without a bed or box installed. The ride is leagues ahead of the stock NPR and far better than any other 4x4 cabover camper, that we have driven. NQO came close to purchasing Matt's 150” wheelbase NPR chassis cab, which is for sale on Expedition Portal as the "Ultimate Expo Vehicle"



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However, we need the 176” wheelbase version to fit the 15’ custom box we are building, so NEVER QUIT asked Matt to undertake another 4x4 conversion, this time using a 2019 NPR that we have purchased. Ours will be similar to Matt's truck (above), but will be tailored to our needs.

After a discussing numerous details for this conversion with Angry Iron Metalworks, NEVER QUIT Overland purchased a 2019 NPR V8 Crew Cab for our conversion. There were no constraints placed upon this build, allowing us to create the ultimate cabover 4WD. As most of you know, Isuzu does not offer the NPS in the United States, however, we know that the NPS has neither the capabilities nor the quality fabrication that our truck will have.

Build Start Date: February 2019

Initial plans are to have the chassis cab completed before the Overland Expo West event in May, then to add a 15’ x 7’ x 7’ box with plenty of room for dogs, kayaks, surfboards and two (tall) adults. We plan to have the camper box completed and installed by September 2019.

Everyone seems to want to know what parts are going into a build, why they were chosen and what the cost is to do a build like this. So, we are going to try to provide some of that information.

This is not a DIY build and we, the customer, NEVER QUIT Overland, has very specific requirements, many of which have determined the design of the truck and the parts list you see below.

Never Quit Never and Never Quit World Tour, put on free large scale running events for deployed members of the U.S. Armed Forces, as well as large scale events in the U.S. and throughout the world.

The truck will travel for events and more throughout North, Central and South America, Australia, New Zealand and Africa with its owner who has lived and traveled to over 55 countries over the past 48 years.

Please feel free to leave constructive criticism or to ask questions about the parts and build process, which will be spread out over three phases and will probably take 8 months to complete, in total. Without further ado, here is the proposed parts list, along with our initial cost estimates.

AXLES:

Front: Dynatrac Pro Rock 80 with 4.88 gears, Eaton E-lockers, 8 on 6.5”, setup for custom leaf springs.

Rear: Dynatrac Pro Rock 80 rear with the same parts, except for leaf perches. A four link suspension will be fabricated for the rear end and the Pro Rock 80 was chosen for its weight carrying capacity. (#11,000)

Approximate cost: $20,000, exclusive of link suspension, custom leaf springs, and installation.

TRANSFER CASE:

A Trail Worthy Fab HERO transfer case was chosen after discussing this project with another transfer case builder, who was honest in stating their case was not the right product for this application. The HERO case can be found in diesel drag trucks, KOH/U4 cars and rock bouncing buggies around the country. You do not want a transfer case failure in the jungles of Nicaragua, so, overkill it is.

The TWF HERO transfer case will be divorced for two reasons: A small drum parking brake is mounted on the tail shaft of the 6L90E transmission, which multiplies the braking force by the ring gear ratio (4.10). Secondly, tearing apart a perfectly good, brand new transmission to swap a 4WD tailshaft onto it, just does not make sense.

Approximate cost: $5,000 retail, per TWF website. Andy is a great guy and provided excellent customer service.

ABS/EBD:

ABS Tone Rings: Isuzu uses a 56 “tooth” tone ring on both axles; though the front has holes and the rear has teeth. Dynatrac has a 55 tooth ring (Dodge), a 48 tooth ring (GM) and a 60 tooth ring (Ford). Obviously, none of these will work, so we will purchase new 56 tooth rings, and Dynatrac will install them during the build, allowing us to retain the factory Isuzu ABS and EBD on our NPS.

Approximate cost: $600, tone rings only, from Isuzu dealer + Dynatrac's installation cost.

SHOCKS / SPRINGS:

Dampers, Front and Rear: This has not been settled yet, but King Shocks is at the top of the list, possibly combined with a custom air bag system in the rear, allowing the ride to be adjusted for road conditions or changes in vehicle weight. Dampers will likely need to be bumped and strapped for safety and longevity.

Approximate Budget: $1,600 plus installation, exclusive of links and bags

Front leaf springs will be custom made for this application once the camper box is completed and all fluids and gear are aboard. Possible vendors are Deaver, Atlas or Alcan and cost is estimated to be $1500-$2000, plus installation, front springs only, rear is links and bags or links and coils.

DRIVELINE:

Driveshafts will likely come from an vendor such as High Angle Driveline or Tom Wood's Driveshafts. Both of these shops have loads of experience building shafts for off road and unusual applications.

Approximate cost: $2500, including spud shaft for the divorced HERO transfer case.

CABLE SHIFTERS:

Cable shifters can be seen in the post linked above, on the previous build and something similar will be fabricated using TWF, JB FAB or NWF cables. This eliminates linkage and allows the case to be shifted easily and smoothly from the driver's seat.

Approximate cost: $1000 plus installation

TIRES & WHEELS:

Nitto Ridge Grapplers in LT285/75R18E were chosen from a small pool of singles that were rated to carry approximately 4,000 pounds each. We explored dual rear wheels, large MPT tires and custom wheels but have settled on these. They are well reviewed and very quiet on the road, even though the tread is said to be between an A/T and an M/T. Two full sized spares will be carried on the truck at all times. Method's 305 Heavy Duty wheels, in black, were chosen for their good customer service, ease of balancing, high finish quality and high load rating (#4500), in an 18” x 9” wheel.

Approximate cost: $3500 for six wheels and tires.

WINCHES:

High capacity winches will be installed front (#17,500) and rear (#12,500), with the rear mounting into a cradle that can only be accessed from inside the camper, to prevent theft. Possible vendors are Smittybilt, SuperWinch, Warn, Runva and RED.

Approximate cost: $4500-$5500, plus installation, soft shackles and 200' of 9/16ths inch 12 strand Plasma rope.

LIGHTS:

Matt is a Baja Designs dealer, so some of their lights may find their way into the truck, but we are also talking to Vision X and Rigid Industries, for camp lighting, driving lights and an LED bar or bars. There are lots of decisions to make here.

Approximate cost: $4000 - $6000 total.

SEATING:

Seats can make or break a trip, so a pair of custom Scheel-Mann seats have been ordered. The rear will have a fold down bench, allowing access to the camper box. High quality seats are not cheap but they reduce fatigue, especially on long highway trips and difficult off road trails.

Approximate cost: $3500 for driver and passenger seats.

MISCELLANEOUS:

Some of the work Matt will perform over the next 3 months, includes custom fabrication of the following:

BUMPERS: front and rear, with lights & winch support.

FUEL TANK: Add an OEM Isuzu 30 gallon (auxiliary) tank with a transfer switch, allowing the fuel load to be spread out some, providing 60 gallons total.

EXHAUST: budget is approximately $1200

A myriad of custom work will need to be performed to complete this one-off conversion with a few such items such as:
  • Skid plates – steel, alloy or UHMW
  • Custom steering linkage to allow push/pull to work on D60
  • Made to measure brake lines to mate NPR to Dynatrac axles
  • Rear Air Suspension (links and bags)
  • Engine and transmission tuning
  • Switchgear, likely from SwitchPro or InfinityBox, but currently TBD.

Much of the fine detail has yet to be decided or is like to change as the build progresses, so we will try to keep this thread updated as progress is made.

That gets most of the major components out of the way. Our truck will be delivered to Matt's shop in about a week and he will start tear down then.

If you are a vendor or represent a company that would like to be a part of this build, please contact us for further details on our upcoming events and adventures.

Thank you for you interest; we hope that you follow along here, on 4BTswaps, or on Expedition Portal. You can also find us on Facebook and Instagram.

Last edited by NEVER QUIT Overland; 03-01-2019 at 03:12 PM.
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Old 02-17-2019, 02:57 AM   #2 (permalink)
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I stopped reading when I saw the budget for LED lighting was $4,000 to $6,000.
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Old 02-17-2019, 04:54 AM   #3 (permalink)
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Lol. Who the fuck budgets 20k for axles and axles and suspension and ďinstallationĒ

If this is staying on the east coast this thing is just going to be a pavement pounder so why even bother with a HERO case.


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Old 02-17-2019, 08:01 AM   #4 (permalink)
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Hi, thank you for your comments.

$20K was budgeted for a pair of Dynatrac axles, excluding suspension and installation.

Quote:
Originally Posted by NEVER QUIT Overland
The truck will travel for events and more throughout North, Central and South America, Australia, New Zealand and Africa with its owner who has lived and traveled to over 55 countries over the past 48 years.
The HERO case was chosen after speaking with several other t-case manufacturers/builders who stated their case would not be up to the job of handling low range in a 12,000 - 13,000 pound, full-time, overland travel vehicle. Andy said his would have no problem with that, so a HERO it is

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Old 02-17-2019, 08:19 AM   #5 (permalink)
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The big dollar builds can be interesting to watch come together but most people here are probably going to give you a hard time on it since DIY is more the norm here. Then again you have guys spending 40K on a buggy that has to be trailered everwhere and is only used to bounce up some rocks for entertainment so really a high dollar RV for either on or offroad shouldn't be shunned to much, just think of what a new off the lot RV costs and this doesn't seem too far out of place.

I say keep reporting in progress but please stop talking about yourself (or yourselves) in 3rd person, I feel like I'm reading a WWF press release.
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Old 02-17-2019, 08:19 AM   #6 (permalink)
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"Database Error" double post

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Old 02-17-2019, 10:15 AM   #7 (permalink)
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Regardless of who is doing the building or how much is being spent, not too many, if any, of us can compete with an actual record like this: "The truck will travel for events and more throughout North, Central and South America, Australia, New Zealand and Africa with its owner who has lived and traveled to over 55 countries over the past 48 years."
It's obviously being built to be used and abused which is just plain cool and it will obviously not be a mall crawler. I want to see more!!
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Old 02-17-2019, 10:19 AM   #8 (permalink)
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awesome. keep the updates and pictures coming, sounds sweet
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Old 02-17-2019, 11:01 AM   #9 (permalink)
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If this is staying on the east coast this thing is just going to be a pavement pounder so why even bother with a HERO case.
Iím surprised that the arenít getting a mdt case. Or at least an iron case 205.
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Old 02-17-2019, 12:43 PM   #10 (permalink)
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Hi, thank you for your comments.



$20K was budgeted for a pair of Dynatrac axles, excluding suspension and installation.







The HERO case was chosen after speaking with several other t-case manufacturers/builders who stated their case would not be up to the job of handling low range in a 12,000 - 13,000 pound, full-time, overland travel vehicle. Andy said his would have no problem with that, so a HERO it is


Iíd look into a oil cooler if that is the worry.

It seems like a case from a military vehicle would have better overall capacity (e.g. larger bearings, larger oil capacity, etc.)


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Old 02-17-2019, 04:04 PM   #11 (permalink)
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Why is this in gen4x4 and not the expedition sub forum?
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Old 02-17-2019, 06:29 PM   #12 (permalink)
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We did look into Meritor and Rockwell transfer cases. They are quite large and very heavy. They are also typically quite old. We felt that a HERO case was a top quality product that would meet our needs to carry the weight and not fail us. It has a good selection of yokes, gear ratios and can be easily cable shifted, which is necessary for a cab over truck.

I cannot figure out how to move the thread to the Expedition section, but I am new to the board. If that is where it should be, then please move it.

Thanks
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Old 02-18-2019, 02:52 AM   #13 (permalink)
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$20,000 on axles? I’d get a Super 60 out of an F550 and grab the matching Dana S135 rear axle for $2,000 and spend another couple grand on gears and lockers. Think of how many more LED lights you could buy with the money saved.

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Old 02-19-2019, 08:49 AM   #14 (permalink)
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Why did you go with a V8 for an expo rig when the Isuzu diesel has worldwide support?
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Old 02-19-2019, 10:02 AM   #15 (permalink)
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one 50" rigid light bar (fancy premier model) is $3k sooooo sadly the lighting budget makes sense to me

axle budget seems fairly reasonable too, those pro rocks are bank

show rigs gotta have the latest and greatest

just please dont put a pop up tent on it
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Old 02-19-2019, 11:21 AM   #16 (permalink)
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Why did you go with a V8 for an expo rig when the Isuzu diesel has worldwide support?
I was watching a video about a land rover trips through Asia specifically Russia, and they didn’t use diesel’s because high-quality diesel is not available in most of Russia and the new fuel systems cannot handle poor quality diesel. So Land Rover chose to put gasoline engines in the vehicles that they were exploring the world i I was watching a video about a Land Rover track through Asia specifically Russia, and they didn’t use diesels because high-quality diesel is not available in most of Russia and the new fuel systems cannot handle poor quality diesel. So Land Rover chose to put gasoline engines in the vehicles that they were exploring the world it with with.
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Old 02-19-2019, 11:57 AM   #17 (permalink)
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I was watching a video about a land rover tracks through Asia specifically Russia, and they didnít use dieselís because high-quality diesel is not available in most of Russia and the new fuel systems cannot handle poor quality diesel. So Land Rover chose to put gasoline engines in the vehicles that they were exploring the world i I was watching a video about a Land Rover track through Asia specifically Russia, and they didnít use diesels because high-quality diesel is not available in most of Russia and the new fuel systems cannot handle poor quality diesel. So Land Rover chose to put gasoline engines in the vehicles that they were exploring the world it with with.
The other large problem that the diesels experience is derate and or full crawl from common emission related failures. The chevrolet LS engines these trucks and the Fuso's run experience worldwide support and better parts/service availability than their diesel counterparts. Even thought the diesels are used around the world many of the emissions related parts are different and unavailable world wide.
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Old 03-01-2019, 03:06 PM   #18 (permalink)
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Our new truck was picked up from the dealership yesterday. We took the opportunity to drive the previously converted 4x4 NPR, so the salesmen and mechanics could see it.

It was quite interesting to see the trucks side by side and to see the reaction of all the Isuzu salesmen and mechanics who seemed to be very interested in the 4WD conversion. Only one or two of them knew that an NPS was available in the ROTW. We also took turns driving the trucks back to back; that was an interesting experience.
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Old 03-01-2019, 03:10 PM   #19 (permalink)
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Lights were delivered to Matt's shop earlier this week, so I asked him to take a few pictures. Some comments have been made about the lights and light budget, but we feel it is very important to have ample lighting in remote camps and driving situations.

So, we chose to add some of Vision X's newest and best products to our truck.

All major components have been ordered, so now it is just a waiting game.

Front axle has been upgraded to Dynatrac Pro Rock 80.

EDIT: The gasoline V8 was chosen for the reasons noted above. There is significantly less emissions hardware, no SCR, DEF or DPF to clog up or fail and no concerns with ULSD or CELs when we are traveling in 2nd an 3rd world countries, which we fully intend to do with this truck.

WRT the transfer case, an iron NP205 was used on the first truck that was built, but there were concerns about the weight on this truck, projected at 12,000 - 13,000 pounds. The HERO case has HUGE straight cut gears, a billet case and 1.75" diameter outputs.
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Old 03-01-2019, 03:53 PM   #20 (permalink)
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Straight cut gears can be very noisy.

Any tcase that size can be taxed with high GVW and v8 power for extended periods. It's the heat that needs to be managed. Have TWF put in provisions for a cooler on it.

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Old 03-05-2019, 03:23 AM   #21 (permalink)
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Following the thread, would really like to see it in person one day
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Old 03-05-2019, 04:51 AM   #22 (permalink)
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Any tcase that size can be taxed with high GVW and v8 power for extended periods. It's the heat that needs to be managed. Have TWF put in provisions for a cooler on it.
You're probably best off picking an off the shelf pump and driving it off the back side of the front output since the last thing you want to be doing is having a custom pump replaced on short notice. The Northstar and 22RE look like they have particularly adaptable pumps. Or you could just toss in one of those $100 12v gear oil pumps but where's the fun in that.
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Old 03-23-2019, 09:36 AM   #23 (permalink)
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Time for a quick Saturday morning update.

Springs from Alcan arrived for the Never Quit truck and Matt was able to get the CAD files that he needed from Warn, Vision X Lights and Isuzu, so that he could draw the bumper in SolidWorks. The renderings on the new shop computer look great. A small version is attached below, the full sized versions are posted here:

[URL unfurl="true"]https://expeditionportal.com/forum/threads/never-quit-overlands-extreme-isuzu-npr-build-4x4-conversion.202717/page-2#post-2606672[/URL]

We are tracking the builds on the HERO transfer case and F/R axles from Dynatrac, with hopes of making OvEx West, but that is not certain at this stage in the game. The bumper will be sent out for CNC cutting and braking next week, then will come back to Matt's shop for weldments and metal finishing, before being sent off to a local powder coating shop.
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Old 05-09-2019, 09:07 AM   #24 (permalink)
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After spending a few days at the Angry Iron Metalworks shop with Matt, I am pleased to share an update. We are getting close to our first test drive and plan to be on the road to Flagstaff this weekend.

Both axles are under the truck, air bags are plumbed in, link bars are installed, U-bolts made, front axle sitting on jack stands, waiting for front shock mounts to be laser cut and powder coated.

Transfer case has been mounted and driveshafts have been ordered. Custom brake lines, driveshafts, an Odyssey PC2150 and a few other items are on their way.
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Old 05-09-2019, 09:12 AM   #25 (permalink)
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A few more pics
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