The Toyota Overlander Build That Balances Capability and Simplicity for True Adventure

Building a Toy Pickup for world travel is one thing, but watching DeskToGlory’s Richard and Ashley transform their 1990 Toy Pickup into a lightweight, simple overland machine is something else entirely. These guys didn’t just throw some parts at their truck and call it good - they methodically upgraded every system with serious thought behind each modification.

Their journey started with an $8,000 budget build that took them from Vancouver to Argentina and back. That original setup used tried-and-true Old Man Emu suspension, which Richard admits was absolutely bulletproof for 100,000 kilometers of punishment. Zero maintenance, zero failures, just set it and forget it reliability. But when you’re planning to drive around the world, sometimes reliable isn’t enough - you want capability that matches your ambitions.

The suspension upgrade represents the biggest transformation in the truck’s evolution. Moving from the factory torsion bars to Total Chaos’s 3.25" long travel kit essentially doubled the front suspension travel from six and a half inches to twelve inches. That’s race car territory for a truck that’s heading to places where the nearest parts store might be a thousand kilometers away.

The Total Chaos kit isn’t just about travel though - it’s about control. Those ICON 2.5" coilovers with piggyback reservoirs and the secondary shocks provide damping that transforms how the truck handles washboard roads and big hits. Richard mentioned pulling some bleed ports to soften the ride on harsh surfaces, which shows the level of fine-tuning possible with this setup. The rear got equally serious treatment with 63" Chevy springs and a complete Sky’s Off-Road hanger kit.

What makes this build smart is the attention to serviceability. Those uniballs in the control arms need periodic replacement, but Richard kept all the factory steering components and refreshed them with genuine Toy parts. The Total Chaos idler arm is rebuildable, which matters when you’re planning intercontinental travel. Having a rebuild kit in your spares box beats hunting for parts in remote locations.

Range anxiety isn’t just for electric vehicles - it’s real when you’re crossing continents in a small truck. The Long Range America 125 liter fuel tank installation solved that problem while avoiding the weight and complexity of rear bumper swing-outs or roof-mounted jerry cans. Richard admits they only needed extra fuel twice on their South America trip, but having 700+ kilometer range opens up route possibilities that would otherwise require careful fuel planning.

The fuel tank installation required some thoughtful engineering. Moving from an in-tank pump to a Walbro inline unit, custom exhaust routing to clear the larger tank, and careful attention to heat management between the muffler and fuel tank. The Russell fittings and quick-disconnect fuel filter make field service possible.

Living space matters on long trips, and the Go Fast Camper V1 provides that indoor sanctuary that roof-top-tent life can’t match. The genius of this setup lies in how the Goose Gear drawer modules perfectly match the truck’s bed rail height, allowing full use of the camper’s side doors. The L-shaped bench configuration with integrated kitchen creates a functional living space that doesn’t compromise the truck’s capability.

Richard’s approach to building this truck reflects real-world experience. The first version got them to Argentina and back, teaching them what they actually needed. The rebuild incorporates those lessons while maintaining the simplicity that made the original so reliable. It’s easy to over-complicate expedition builds, but this truck strikes the right balance between capability and complexity.

The Total Chaos suspension transforms the truck’s personality completely. Richard’s demonstration of hitting whoops at speed shows capability that simply wasn’t possible with the original setup. But he’s also realistic about how this capability gets used - it’s not about jumping the truck, it’s about having control and comfort when conditions demand it.

You can follow their adventures and get detailed build information at desktoglory.com.