Overland Expo West 2023

We are now 14 years into this Overland Expo thing, and based on the 2023 edition of Overland Expo West, enthusiasm for the event is as strong as ever. The original Overland Expo continues to be a gathering of community where folks from all over the world and all walks of life spend the weekend catching up, checking out the latest gear and vehicles, and attending classes on everything from Drones to Driving techniques.

As is tradition, I logged 10’s of thousands of steps walking around the vendor booths, moseying through the campgrounds, dropping in on classes in both the classrooms and driving area to try and capture a sampling of everything that is Overland Expo. In no particular order, here is a selection of cool stuff from Overland Expo West 2023.

Black Rhino / Axial – Booth engagement is a thing – how do you draw folks walking down the aisle into your booth? I think the Black Rhino crew figured this one out by partnering up with Axial RC to make a RC crawling course where the fastest time won a set of wheels. Scale RC cars are pretty neat, and this sixth scale Axial rig had my attention.

TRED – TRED Outdoors had a some properly burly screw-in stakes and their new line of vehicle leveling products on display. Hit their website for all of the details on their new leveling products which look well made and well thought out.

ARB – The folks at ARB have been busy working on everything from the new 2024 Tacoma to a host of other products for other platforms. The new summit bull bar pictured for the 3rd gen. Tacoma looks brilliant, as do the new Ford Bronco bits like the compressor mount and JACK mount. ARB is expanding their rack offerings with new platform and bed rack options.

74 Weld – Speaking of impressive Toyota parts, 74 Weld had their portal axle kit on display, which makes stuffing 37’s on a 3rd gen taco an easy thing. The kit uses OEM geometry, and provides the gear reduction to maintain factory ratios. Plus, you get disk brakes on all four corners.

LEXUS – It’s always interesting to see which OEMs are going to show up at Overland Expo on a given year, and 2023 marks Lexus’ first appearance at the show. GX / LX Overland builds are verymuch a thing, so it’s always good to see an OEM recognize what their customers are doing.

GMC – AT4X all of the things! GMC is applying the AT4X treatment to all of their truck platforms from the Canyon up to new new Silverado HD. In partnership with AEV, these rigs are turn key with fancy shocks, lockers, and real armor so you can just load them up and go have fun. A detail I appreciate is the ability to remove the steps from the rock rails shown on the Canyon AT4X.

EQUIPT – The Paul May isn’t scared of a little electronics work in the rain, and I happened to catch Paul in the middle of installing a new control board in a National Luna fridge. This retrofit control board adds Bluetooth control to most all National Luna fridges (check with Equipt for your specific model), so NL owners do not have to shell out for a new fridge to take advantage of the company’s latest wares. Equipt also had Eezi-Awns new sword hard shell root tent on display.

AT Overland – The Aterra Truck Topper and Aterra XL Camper we’ve had the opportunity to check out at Desert Rendezvous made it’s official debut at Overland Expo. The Aterra Topper is a particularly appealing option for anyone who is interested in a slide in camper.

GOOSE GEAR – The new Park Series from Goose Gear is a DIY interior system for Subarus and Toyota Rav4s – and it looks just as awesome as any other Goose Gear system. Goose Gear also had their new interior for the Scout Tuktut on display as well.

Dometic – Dometic is continuing to press headlong into the Overland-o-sphere with a new roof top tent and inflatable shelter system. The TRT 140 roof top tent uses air poles instead of aluminum to save a little weight up high on your vehicle and the HUB 2 is the inflatable version of an EZ-UP. Color me interested to see how these new products work.

Overland Kitted – The folks who have been the US importer for MAXTRAX have launched mounting systems for MAXTRAX recovery boards, and other externally mounted accessories (rotopax shown for example). They’ve also got the lastest from InDeFlate – a digital two hose unit.

Kakadu – New to the US market, this established Aussie brand has some great kit on display like their 1P and 2P sleep systems. They were also showing off a very interesting shower system and based on the specs and initial impressions it all looks very good.

Surefire – Piece of the sun in your pocket maker Surefire had a couple of their new Turbo EDC lights on display at Overland Expo. The EDC2 and EDC1 lights are specifically designed to project light to extreme distances and can be powered by 123s or rechargeable 18650 cells.

Kelty – It’s always interesting to see how established outdoor brands approach the overland industry, and Kelty had an appealing selection of gear on display. Their Backroad and Sideroad awnings are great options for affordable, packable shade that work with SUVs, trucks, or vans, and their multi-seat chairs are always a win.

Rollercam – The company that reinvented the cam strap now has a solution for anyone who can’t remember a trucker’s knot, or anyone who likes an easy to use solution for tying stuff down. The Roperoller works just like the Rollercam, and is a game changer for anyone who has struggled to guy something off.

Zero Breeze – A/C for Overlanding is officially a thing. It will be interesting to see how this segment of the market fares in the coming years.

Tembo Tusk – The company known for the Skottle actually started off as a fridge slide company, and their latest product is a tilting fridge slide. As always, the Tembo Tusk crew were throwing down on their Skottles all weekend serving up all sorts of food.

Total Chaos – If you’ve heard about how some older Toyotas had issues with their lower ball joints suffering a rapid unscheduled disassembly – here’s your fix.

Arctic Trucks – The legendary Icelandic manufacture of vehicles that have driven to both poles of the planet is now established in the United States. Having watched videos of these trucks in action for so many years, it was a treat to see one in person and nerd out with the folks from Arctic Trucks USA.

RUX – Bags are a dime a dozen – everyone makes them, so how do you stand out? You make bags like Rux. This Canadian manufacture uses RF welding to build some extremely well thought out bags that are absolutely worth checking out if you like well made, highly functional, durable gear.

Polaris – UTVs are officially overland vehicles. Polaris’ new line of Side-by-Side / UTVs have all the farkles, enclosed cabs, heat, A/C, and a price tag that makes some mid-sized trucks look like a deal.

Step 22 Gear – Step 22 gets a crisp high five for making custom laser etched patch labels which work great on all of their awesome bags or any other place you need a label. Their bags and mounting panels like the Reef shown here continue to impress with their design and attention to detail.

Deep Cycle Systems – Another example of more awesome from Aussieland are DCS batteries. Featuring shapes and sizes that can fit in the voids left in many vehicles and high charge / discharge ratings, these batteries look awesome.

2024 Tacoma – Toyota pulled the cover off of the all new 4th generation Tacoma at Overland Expo. Two models were on display – a PreRunner which initially had a gigantic snow plow of an air dam that mysteriously disappeared shortly after the launch, and the Trailhunter which is directly targeted at the overland crowd. Let us know in the comments what you think about the new Taco!

Classes – Overland Expo has classes on everything: From the expected offerings like driving, spotting, and recovery, to more wildcat offerings, there hundreds of hours of courses availible so the challenge becomes picking the courses that interest you the most.

Cool Rigs – It’s always a treat to get to take a walk through the campgrounds at Overland Expo. Here you’ll find a spectrum of setups as unique as the people that use them. To a person, everyone I chatted up about their camping setup was more than happy to talk to me and generally stoked to be out actually using their gear. It just goes to show – it doesn’t matter what you drive or where you sleep, but that you’re out there actually doing the the thing.

THE BIG PICTURE – Early in 2023, Lodestone Events announced that they had been acquired by Emerald Expositions – the company that puts on industry trade shows like Outdoor Retailer. Yet from a boots on the ground perspective, not much has changed. Overland Expo continues to be run by the same small crew of passionate folks, and many of the familiar faces can been seen making the event run. Time will tell how this new owner changes the heading of their latest acquisition. Despite some classic Flagstaff spring weather (it rained hard on Friday), the show saw plenty of attendees, and the venue seemed to be mostly full of vendors.

Speaking of vendors, most all of the familiar brands were there, and while there is a trend of new names continuing to sell the same Chineseium with their stickers on it (recovery gear and roof top tent cloners I’m looking at you.) there continues to be cool and new things coming market – you just have to seek out the quality kit. One thing that hasn’t changed is that there is no shortage of cool stuff on display. If you attended OXW 2023, let us know about your experience in the comments!

3D Printing and Vehicle Modification

3D Design for a sPOD SourceLT and Universal Mount

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?

3D printed Quick Fist Mount

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
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

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.

Further Reading

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.