NEVER QUIT Overland's Extreme Isuzu NPR Build & 4x4 Conversion

DzlToy

 
Joined
Jan 11, 2005
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123
I am posting this for two friends; one is building the truck and one is the owner/customer.

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...

2015 Isuzu NPR Crew cab 4x4 Ultimate Expo Vehicle

1904820


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, have very specific requirements, many of which have determined the design of the truck and the parts list you see below.

www.NeverQuitNever.com and www.NeverQuitWorldTour.com 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 80
with 4.88 gears, Eaton E-lockers, 8 on 6.5”, setup for custom leaf springs.

Rear: Dynatrac Pro Rock 80 with the same parts, except four link suspension instead of leaf. 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. There is some evidence that Isuzu's version of this transmission is a bit of a hybrid and that the 4WD tailshaft found in Silverado and Tahoe vehicles, would not bolt up.

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, 48 & 60 tooth rings, but no 56. So we will purchase new 56 tooth rings, and Dynatrac will install them during the build, gratis, 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:
King Shocks combined with custom air bag system in the rear, allowing ride to be adjusted for road conditions or changes in vehicle weight. Dampers will 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:
https://www.nittotire.com in 285/75R18E. Load rating: #4,080. Well reviewed, very quiet on road. Tread between A/T and M/T. Two full sized spares will be carried on truck at all times. Cost: $2,000 (Includes sensors, w/ rebate)

Method's 305 Heavy Duty wheels. Load rating: #4,500. Color: Matte black. 18” x 9” wheel. Bolt pattern: 8 x 6.5. Offset: +18 Part #:MR30589080518H, Cost: $307.45 x 6 = $1,900

https://www.methodracewheels.com/co...cts/305-nv-hd-matte-black?variant=29570143297

WINCHES: Warn with synthetic line

Front: 16,500 pounds - Cost: $1,967.
Rear: 12, 500 pounds - Cost: $1,327
Total cost = $3450 including shipping

LIGHTS:

For all truck and camper lighting, we have chosen Vision-X lights. Please see post below for a detailed list.

Approximate cost: $4000 - $6000

SEATING:

Custom Scheel-Mann driver & passenger seats. These are the world's most comfortable and best made seats. Contact Toby at: scheel-mann.com

Approximate Cost: $5,000

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: https://www.expeditionportal.com/fo...xtreme-isuzu-npr-build-4x4-conversion.202717/

Facebook: Never Quit Overland

Instagram: NEVER QUIT (@neverquitoverland) • Instagram photos and videos
 
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DzlToy

 
Joined
Jan 11, 2005
Messages
123
A few updates have been made to the original post and we will try to keep it updated as changes are made to the build sheet instead of making a new post each time. Lighting details would not fit in the first post, so they follow below:

A few updates have been made to the original post and we will try to keep it current, as changes to the build sheet are made, instead of making a new post each time. So please refer to the first post for current specs and products.

Winches have been ordered, wheels and tires have been ordered, seating description was edited and front axle was changed from a D60 to a D80, due to a spring perch issue. There is a small weight penalty, about 30 pounds but a Dana 80 front end is BEEFY, so we will never have to worry about breaking it.

This truck will be at Overland Expo and it appears that you won't be able to miss it with all of these lights on. :D

As the list of lights is quite extensive, the info would not fit in the first post, so it follows here:

LIGHTS:
Vision X. Best built and brightest: Phone: 888-489-9820

(Roof Mount) XPR-3S
> 6" XPR 10-WATT LIGHT BAR 3 LED SPOT OPTICS FOR EXTREME DISTANCE)
6" XPR 10W LIGHT BAR 3 LED SPOT OPTICS FOR XTREME DISTANCE

(Roof Mount) XPR-3S > 6" XPR 10-WATT LIGHT BAR 3 LED SPOT OPTICS FOR EXTREME DISTANCE)
6" XPR 10W LIGHT BAR 3 LED SPOT OPTICS FOR XTREME DISTANCE

(Roof Mount) XPR-27S > 51" XPR 10W LIGHT BAR 27 LED SPOT OPTICS FOR EXTREME DISTANCE
51" XPR 10W LIGHT BAR 27 LED SPOT OPTICS FOR XTREME DISTANCE

(Bumper Mount) DURA-M460FLUSH > FLUSH MOUNT DURA MINI - 4 LED 60 DEGREE
https://www.vxautomotive.com/3in-Fl...D-Mini-Dura-Work-Light?keyword=DURA-M460FLUSH

(Undercar Rock Lights) HIL-RL6W > 9 WATT LED ROCK LIGHT 6 POD KIT WHITE
9 WATT LED ROCK LIGHT 4 POD KIT AMBER

(DOT Headlight Bulbs) VX-DH4 > H4 55/60 WATT HI/LOW DOT APPROVED SUPER WHITE BULB SET
H4 55/6 WATT HI/LOW DOT APPROVED SUPERWHITE BULB SET

(Bumper Multi LED’s) CG2-CPM710KIT > PAIR OF 4.5" 7 LED CANNON CG2 LIGHTS INCLUDING HARNESS USING DT CONNECTORS
PAIR OF 4.7" 7 LED LIGHT CANNON GEN 2 INCLUDING HARNESS USING DT CONNECTORS

(Bumper Focused LED’s) CG2-CPZ110KIT > PAIR OF 4.5" SINGLE SOURCE 40 WATT CANNON CG2 LIGHTS INCLUDING HARNESS USING DT CONNECTORS
PAIR OF 4.7" SINGLE SOURCE 4 WATT LIGHT CANNON GEN 2 INCLUDING HARNESS USING DT CONNECTORS

(Grill Lights x4) CGA-CPMH8MKIT > PAIR OF 6.7" CANNON ADV HALO 8 LED LIGHT MIXED BEAM INCLUDING HARNESS
PAIR OF 6.7" CANNON ADV HALO 8 LED LIGHT MIXED BEAM INCLUDING HARNESS

(Brand New Shocker Bar, see attachment) SHK-BV24WPA > 40" SHOCKER 24 LED BAR DUAL MODE WHITE LIGHT VECTOR AND AMBER PHOTON LIGHT PIPE NO HALO FUNCTION

Retail Cost: $7,100. (this does not include side and rear lights. (add another $1,600)
 

DzlToy

 
Joined
Jan 11, 2005
Messages
123
I stopped by Matt's shop yesterday to give him a ride to the dealership and pick up the new NPR. 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. I am looking forward to seeing this truck on the road.

1917119



Lights were delivered to Matt's shop earlier this week, so we opened the boxes and made a display. Some comments have been made about the lights and light budget, but the owner feels it is very important to have ample lighting in remote camps and driving situations. He will be traveling in 2nd and 3rd world countries on a regular basis. The ground moves with creepy-crawly things in many of these places, :D

So, the owner has chosen to add some of Vision X's newest and best products to his truck.

1917120


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 over the 5.2L diesel for a few reasons. There is significantly less emissions hardware, no SCR, DEF or DPF to clog up or fail and no concerns with ULSD or CELs when the truck is in 2nd an 3rd world countries, which is where the owner intends to use it.

Some comments were also made about using an NP205 or an MDT transfer case. An 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, and the use of that case. The HERO case has HUGE straight cut gears, a billet case and 1.75" diameter outputs, so it was chosen for this application.
 
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Wow great project. I will be following along. Just asking, All the chosen component seem super Beefy except the tires 4080lbs per tire seem a bet lite for the rear singles ?
PS The truck looks SICK!!!!!
 

mr jits

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HERO case has HUGE straight cut gears, a billet case and 1.75" diameter outputs, so it was chosen for this application.
Wow great project. I will be following along. Just asking, All the chosen component seem super Beefy except the tires 4080lbs per tire seem a bet lite for the rear singles ?
PS The truck looks SICK!!!!!
I'm pretty sure the Hero case gears are no stronger than those of an NP205. Plenty of guys out there running 205's with 56" tires not having transfer case issues. Honestly, a 205 with a NWF magnum box would give great gear choices (having a true low/low in bad traction situations is a lifesaver).
The tire choice is silly. It's going to look good, but they'll be underrated for the vehicle weight, let alone a rig loaded for over landing. There's a reason that Unicat, MAN, Unimog, etc. use Goodyear/Michelin commercial/military tires rated at 7500 lbs or more per corner.
I dig the build ideas, but they're not too receptive to suggestions or criticism of their plans over on expo, so I'm more keen to sit back with the popcorn and see how the travels pan out.
 
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cruisermatt

ランドクル62!
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This seems like a really big expense and inefficient way to carry two adults some dogs and some surfboards. Why not just put a light bar on a school bus or a moving truck ?
 
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Your using a gasoline v8 for a 12k lb truck? That will be a anemic vehicle. Why not start with a older chassis that has a mechanical diesel Cummins of some sort that has no emissions? For the money spent on a new npr, a old truck could be purchased and totally revamped and emissions left out of the picture.
 
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