Front Runner Outfitters : American Adventurist

The affordability of 3D printing has changed the way I modify my vehicle. Not long ago if some part didn’t exist that fit my need I had to do without. A lot has changed over the years but how did all this lead me to making my own parts? How did I end up making this?

Before 2010 manufacturing my own parts wasn’t a reasonable option.

Charles W. Hull invented the stereolithography printer in 1986. In 1987 you could purchase the SLA-1 Original 3D Printer for about $300,000 UDS. The equivalent in 2023 value is just over a million dollars. For the next 20 years 3D printing and rapid prototyping was was out of reach for most people leaving just the traditional manufacturing process.

Between 2004 and 2005 the interest in low cost 3D printers skyrocketed when Dr. Adrian Bowyer, a Senior Lecturer in mechanical engineering at the University of Bath in England, introduced the idea of 3D printers that could self-replicate. The project named RepRap (‘REPlicating RAPid prototyper’) was open source and interest in low cost 3D printing spread worldwide.

Rep Rap Version I: Darwin 3d printer
Source: https://reprap.org/wiki/Darwin

Then the 3D Printing landscape changed in 2009. Charles W. Hull’s patent of stereolithography (SLA) and Stratasys’ patent for fused deposition modeling (FDM) technology expired. New DIY kits became available and competition for the new non-commercial user market drove prices for DIY 3D Printer kits even lower.

2010 and Maker Culture

During the early 2010’s, around the time Formlabs Kickstarter campaign for the FORM 1 began, online 3D printing service companies like Shapeways, Sculpteo, i.materialise, 3D Hubs, etc. moved to capitalize on the growing interest of 3D printing and the emerging market of low production number 3D printing. Offering multiple printing materials and the ability to print larger then a typical DIY 3D Printer. For individuals and small companies who didn’t want to or couldn’t afford to invest in a commercial 3D Printer it offers the capability of rapid prototyping without the upfront cost. By 2018 the 3D printing industry was generating more than $7 billion in revenue.

So here I am

It’s in this environment that I found myself looking for a part that didn’t exist. A Quick Fist mount for a Frontrunner roof rack. Having some CAD experience I was fascinated by the prospect of being able to manufacture my own parts so I dived in.

Not without mistakes of course. There’s an expression “fail fast, fail often” and by that measure my first attempts were an astounding success. If you plan on taking the same dive my advice is to literally start small when using online 3D printing services. You pay as much, if not more, for the volume of the object you wish to print than for the materials. Also invest in a precision measuring tools. Just eyeballing it will get expensive fast.

Eventually the incline of the learning curve began to level out. I also found myself in need of another impossible to find part. A relocation kit that worked with the OEM Tacoma backup camera and a custom rear bumper. It took several reprints to get the pitch of the camera correct as well as understanding the tolerances of the materials. Being a relatively small part the experience was worth the cost of the do-overs.

From There to Here by Just Making Stuff

Following is a sampling of the progression of the complexity of the parts I had manufactured. It also highlights a transition into creating parts to address an afterthought to that of being part of the modification from the very start. From filling in a need with a camera relocation mount on a bumper that didn’t have one. To making improvements on something that was satisfactory by cleaning up a solar panel cable pass through for a project that was in progress. To planning the location of a compressor switch and quick disconnect and working the other components in to fit within that design plan.

3D Printer Design of a Toyota Tacoma OEM Backup Camera relocation mount — Toyota Tacoma OEM Backup Camera relocation mount

3D Printer design of the Cascadia 4x4 VSS System / Deutsch connector bracket — Cascadia 4×4 VSS System/Deutsch connector bracket

3D Printer design of the ARB Compressor switch and quick disconnect mount — Tacoma interior ARB Compressor switch and quick disconnect mount

3D Printed mount used to relocating the backup camera to the rear bumper swing arm — Backup camera relocated to the rear bumper swing arm

3D Printed VSS System/Deutsch bracket mounted to the windshield cowl. — VSS System/Deutsch bracket mounted to the windshield cowl

3D Printed ARB Compressor switch and quick disconnect mounted in a Tacoma — ARB Compressor switch and quick disconnect behind the driver’s seat

You need only time to start manufacturing your own parts

3D printing services will vary in costs, materials available, and limitations of the size of the printed object. Online CAD services will vary in the design of the user interface as well as the file formats available for download. Each have their own advantages and disadvantages. Including their location to take advantage of shipping time and/or currency exchange rates.

My current project is a sPOD SourceLT / universal mount for the engine bay of a Subaru Crosstrek. I don’t own a 3D Printer or CAD software. It, and everything I’ve designed and had manufactured, exists through using some of the services I’ve listed below. The lists are by far not exhaustive but they will help you get started.

sPOD SourceLT / Universal Mount for the Subaru Crosstrek.

3D Printing Services

3DPRINTUK – UK
i.materialise – Belgium
MakeXYZ – USA
Protolabs – USA
Sculpteo – France
Shapways – Holland / USA
Stratasys Direct – USA
Xometry – USA

Browser-based CAD programs

Onshape – Mechanical Engineering / Advanced Product Design
SelfCAD – 3D Printing / Beginners
Sketchup – Architecture / Product Design
TinkerCAD – Beginners / Education
Vectary – Product / Graphic Design
Fusion360 – Advanced Features / Free for non-commercial use.

I’ve used Sculpteo and Shapeways printing services. Both are similar in printing materials available and in price with Sculpteo being less expensive than Shapeways with some materials. Of the browser-based CAD programs I’ve only used Sketchup. Mostly because I’ve used it since Google acquired (and later sold) the original creator @Last Software and all its quirks are familiar to me.

We want your input

We invite you to participate and constructively contribute. Are you using a different online service that’s not listed here that you want to recommend? Let us and the readers know by joining our community.

FULL DISCLOSURE: The products and services mentioned in this article were paid for by the author.

Enjoy the ride as we look back at TEN YEARS of Overland Expo! Lodestone Events has entered the game, and 2019 is shaping up to be even bigger than previous years so please stop by and say hi at the American Adventurist booth at site PS1. We’ll have a cold beer ready for you courtesy of Wanderlust Brewing in Flagstaff, bring your cup!

In 2009 at the Yavapai Fairgrounds in Prescott, Arizona, an ambitious group of like minded travelers gathered for something new. Something called Overland Expo.

Before 2009, roof top tents, 4WD vans, off-road campers, Glamping, Overlanding, all of it was virtually unknown in North America. Yes, some of the gear was around, and car camping was hardly a new thing, but Yakima didn’t sell awnings yet, and Walmart wasn’t dabbling in 12 volt fridge/freezers. It was more of a “you need to know a guy” to get a roof top tent or 12 volt fridge back then.

Overland style gear and builds were quite rare in the mid to late 2000’s, and gathering them all in one place was unheard of. Even more exotic were the tales some of these people told, with many miles traveled by 4WD in Africa, Australia and other distant lands.

Legend says that around 900 people attended that first event along with a handful of pioneering companies: Equipt, Adventure Trailers (AT Overland), Land Rover, Baja Designs, ARB, Viking Offroad, Four Wheel Campers, Ursa Minor, KC Hilites, Autohome USA, Sportsmobile, Overland Journal, Aluminess, and Global Expedition Vehicles. These are the Plank Owners of Overlanding in America as we know it.

Organized and led by Jonathan and Roseann Hanson, that first Overland Expo was the catalyst for the Overland mania that is now mainstream. Today, this event draws top automakers, hundreds of outstanding companies, and tens of thousands of eager enthusiasts. Few dared to imagine back then that it would have grown to be the largest event of it’s kind in the Western Hemisphere, fueling a global, multi-million dollar Overland Industry.

Mark Twain said ““Travel is fatal to prejudice, bigotry, and narrow-mindedness, and many of our people need it sorely on these accounts. Broad, wholesome, charitable views of men and things cannot be acquired by vegetating in one little corner of the earth all one’s lifetime.” I think if Mark Twain were here today he would be proud of the community that grew up around Overland Expo.

[vc_row][vc_column][vc_column_text]I still remember their second Overland Expo in 2010 at the Amado Territory Ranch in Arizona like it was yesterday. The entire Overland thing was still in it’s infancy and it was there that I met Jerry from Tembo Tusk, before anyone ever heard of a skottle. It was in Amado that I contracted the Snow Peak virus, a mishap that cost me more than a few dollars in “must have” glamping equipment over the next decade.

I shared midnight tequila with the late Al Walter and company in Amado, remembering favorite Baja trips while Al regaled us with his vast knowledge of obscure places and desert history. It was at Overland Expo that I got to hang out with people like Chris Marzonie, the Baja Taco himself. I had a beer with Scott Brady from Expedition Portal, and partied with the likes of Mario Donovan from Adventure Trailers and Paul May from Equipt before they were Overland Rock Stars.

All the coolest people were there, and it was there that I realized I wasn’t that weird, and I found many others just like me, eager to follow the paths less traveled while exploring the most remote places in the world.[/vc_column_text][vc_media_grid grid_id=”vc_gid:1557774108123-abc7103f-1d6e-3″ include=”9042,9036,9034″][/vc_column][vc_column][vc_column_text]Overland Expo was also my first look at many, many exotic 4WD’s and top-shelf vehicle builds. As a career military guy, “vehicle dependent expeditions” were nothing new to me but this new Overland thing was very, very different. I learned that I could eat well in the field, have hot coffee and cold beer, and above all I didn’t have to sleep on the ground unless I chose to. It was even possible to have a hot shower in camp.

So many things that I loved were blending together in one place: travel, 4WD’s, camping, cooking, training, gear, motorcycles, and the stories these activities produced. The Expo was blurring all the lines and I was all in.[/vc_column_text][vc_masonry_media_grid grid_id=”vc_gid:1557774108130-aa9ac40c-8be1-1″ include=”9098,9097,9095,9062,9094,9096,9054,9056,9092,9068,9067,9065,9066,9064,9063,9061,9046,9041,9045″][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]More than just a trade show, the Hanson’s brought in concepts like education, hands-on training, environmental responsibility, community service, and film festivals making the event greater than the sum of it’s parts. Above all, I was fascinated by the quality of people that I met at the Expo, and I left that event personally inspired to become better educated and better traveled. This all came at a time in my life when I was suffering from some combat related survivor’s guilt as well as recovering from my own deployment injuries and really needed “something” to focus my own surplus energy on.

Attending that Overland Expo in Amado inspired me to found American Adventurist, and I started organizing my own Desert and Mountain Rendezvous events that same year.

Thank you Jonathan and Roseann for inspiring us.

[/vc_column_text][vc_media_grid grid_id=”vc_gid:1557774108155-db63c481-078e-1″ include=”9075,9076,9077″][/vc_column][/vc_row][vc_row][vc_column][vc_media_grid element_width=”6″ grid_id=”vc_gid:1557774108159-9512a648-87f3-10″ include=”9044,9057″][vc_media_grid element_width=”6″ grid_id=”vc_gid:1557774108162-9b88b2d2-e723-3″ include=”9040,9052″][vc_column_text]Fast forward a bit as Overland Expo grew. And grew. The American Adventurist crew attended every year in Mormon Lake and then at Fort Tuthill. When they added Overland Expo East at Taylor Ranch, we expanded too with our first Appalachian Rendezvous in North Carolina. We attended Overland Expo East at the Biltmore and then at the Reeb Ranch. We met thousands of amazing people and became involved in land stewardship and access issues.

I am unaware of any other events that have inspired such a fast growing, diverse, and dedicated following as Overland Expo.[/vc_column_text][vc_media_grid grid_id=”vc_gid:1557774108165-918ed293-5e06-0″ include=”9091,9086,9090″][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]Looking back now on 10 years of events we have nothing but good memories – Underwater Expo, Snowverland Expo and Mudderland Expo included. For those of you who were there well… if you know, you know!

Challenging weather, the tyrannies of time and distance to travel to these events, in our experience it was all worth it to attend these grand family reunions. The one family reunion that you don’t have to dread going to each year. Where else in the world can you learn so much, see so much, and do so much in one weekend?[/vc_column_text][vc_masonry_media_grid grid_id=”vc_gid:1557774108168-f602e6c7-a740-6″ include=”9058,6362,9069,7070,9060,9050,9051,9070,9049,9052,9059,9055,9043,9054,9085,6597,6578,6589,6566,6560,6562,6559,6543,6508,6492,6479,3790,3762,3767,1679,1676,1677,1650,1699,1688,1638,3855,3854,3840,3838,3848,3835,3825,3817″][/vc_column][/vc_row][vc_row][vc_column][vc_column_text]So what did we learn along the way at Overland Expo? Too much to list really, but here’s a few salient points that may be of help to anyone attending for their first time:

The 7P’s aka Proper Prior Planning Prevents Piss Poor Performance. Always be prepared for the wind, the wet, and the cold. Or blazing heat. Or monsoons and mud. There are no guarantees when it comes to weather, and there’s no such thing as bad weather, only bad gear.
Site Selection. Just in case weather happens, select a camp site that provides for good, rapid water runoff and wind-blocking protection if at all possible. Tent and vehicle placement to take advantage of prevailing wind conditions is critical to maintain a stable structure. Arrive early for best results.
Meal Planning. Plan your meals carefully in advance to save time and preparation, you’re going to be on your feet a lot at an Expo and being prepared with easy meal plans pays off.
Be prepared to have FUN. We’ve made so many great friends at Overland Expo, and every year brings a wild bazaar of the latest goods and services sprinkled with happy hours with friends old and new. Bucket list trips and new business partnerships take root here every year.
Bring some walking around money. You don’t know it yet, but there’s something shiny there that you need that you’ve never seen before. Trust us when we say shiny squirrels abound.

[/vc_column_text][vc_media_grid grid_id=”vc_gid:1557774108218-de3af5f0-cee8-9″ include=”7347,7399,7343″][/vc_column][/vc_row][vc_row][vc_column][vc_masonry_media_grid element_width=”3″ grid_id=”vc_gid:1557774108223-77a3125c-8be6-8″ include=”7440,7439,7437,7433,7428,7429,7423,7418,7420,7397,7391,7372,7353,7349,7340,7335,7345,7997,7954,7580,7456,7333,7426,7443,7377″][vc_column_text]Today, the Hanson’s have handed over the keys, and Overland Expo West 2019 marks the first year with Lodestone Events at the helm. We’re confident that it’s in good hands, and we look forward to seeing what they do to take it to the next level. With well over 10,000 like-minded enthusiasts headed to Overland Expo West, it’s guaranteed to be a show for the record books. Again.

So stop by and have a beer with us at Overland Expo West 2019 courtesy of Wanderlust Brewing in Flagstaff. Grab some swag from us, trade some patches, grab a raffle ticket to win a set of Falken Wildpeak tires at 3pm on Saturday, we’d love to hear your story and how this community of interest impacts YOU.

See you out there!

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Event photos used with the express permission of Overland Expo and Exploring Overland.

Additional photo credits and thank you to: Chris Collard, Chad de Alva, Richard Soohoo, Chris Griggers, Bryon Dorr, Chazz Layne, David Croyle, Bosque Bill, Adventure Trio, Mike Petrucci and Gary Haynes.

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Tag: Front Runner Outfitters

3D Printing and Vehicle Modification