In Rufus, our expedition truck, both the front and rear axles were replaced during a 4x4 conversion. Unfortunately, neither of the new axles included ABS provisions that matched the factory setup. To restore ABS compatibility, we fabricated new tone rings and sensor mounts that matched the factory signal parameters.

We knew from the start we’d be keeping the tried-and-true leaf spring suspension system on Rufus. While there are plenty of modern suspension options, the simplicity, durability, and reliability of leaf springs made them a perfect fit for our build. In this post, we’ll dive into the different types of leaf springs in Rufus, why we chose to stick with them, and what you need to know to order and modify them for your own project.

In our overland vehicle, Rufus, we decided to install a central vent manifold. This solution consolidates the breathers from all critical components and routes them to a single, elevated manifold. Mounted high in a location where it’s unlikely to encounter water, this central vent system provides peace of mind during water crossings.

After 10,000 miles on the road (and off), we’re taking a hard look at how our front axle setup and supporting mods are holding up. Here’s what worked, what didn’t, and what we’d do differently after thousands of miles of real-world testing.

While the Dana 60 is known for its legendary strength and reliability, we knew we could make it even better for our demanding needs. Here’s how we rebuilt the axle from hub to hub, addressing common weak points and making the necessary upgrades to ensure it’s ready for years of adventure.

Requirements and considerations for choosing a front axle for our DIY expedition truck.

We’ve put about 10,000 miles on our 4x4 swap, which means our rebuilt Dana 80 rear axle has seen the same. It's time to check in and evaluate what’s worked, what hasn’t, and what we might change in the future.

When building a reliable overland vehicle or expedition truck, few components matter more than the rear axle under your rig. Now that it’s in our hands, it’s time to rebuild, modify, and upgrade it to meet the unique demands of life off the grid.

Our rear axle isn’t just about moving us down the road—it has to perform in all conditions with absolute dependability. On top of that, it had to meet a few critical requirements: the right width, a heavy weight rating, and compatibility with aftermarket gears and lockers. After weighing our options, the choice became clear: we went with a Dana 80 axle. Sourcing it was another story!

Goodbye Stock Axle, Hello Dana 80: Building a Better Foundation for Rufus. When we began building Rufus, our expedition truck, we quickly realized the factory axle could work… but only with significant modifications. Instead, we decided a rear axle swap was the smarter move for reliability, gearing options, and long-term parts availability. Here’s how we made the decision and why we ultimately chose a Dana 80.

Our unit is over 50 years old, but after a complete rebuild with high-quality, USA-made bearings, gaskets, and seals, we expected it to handle anything we could throw at it. Now, with 10,000 miles on the build, this is our NP205 review—covering what works, what we’d change, and how it fits into a modern overland build.

Upgrading our NP205 Transfer Case with a Cable-Shifted Twin Stick. While most modern transfer cases use electronic controls — buttons, knobs, or switches — our NP205 is an old-school, fully mechanical unit.

 Learn how to mount a divorced NP205 transfer case using a custom-built crossmember designed for strength, flex, and precision. Perfect for beginners tackling DIY off-road driveline upgrades.

We bought a pair of 50+ year old New Process 205 (NP205) transfer cases off Facebook Marketplace after they sat outside next to a shop for years, waiting for a build that never came. Here we document the tear-down of these two cases and consumables needed to create one like-new transfer case for our overland rig, Rufus!

As an integral part of a 4wd system; it may seem odd to rely on a piece of machinery from 1973 as a base of our 4x4 swap…in a brand new truck! In this post we consider different transfer case options and explain why in this case, old is gold.

With so many camper options on the market, how do you decide what is the best option for your needs? 7 key factors to consider when choosing your overland camper.

Normally, we get blank stares when people ask what truck we are using to build our adventure vehicle and we respond with Chevy 4500 LCF (Low Cab Forward). Here is why we think it is an awesome, and often overlooked, option!

How did we find ourselves tearing apart a brand new truck to convert to 4×4 and build a camper from scratch? How ‘Ramble on Rufus’ began and what drives us forward!