Shop Build · Overland Pickup
The Shop Tundra.
2005 Toyota Tundra. Built for Baja.
Our shop truck. A 1st gen Tundra Access Cab rebuilt around a single mission — get to Baja, surf for weeks, get home. Boxed frame, Dana 60, ADS suspension, MITS Alloy tray and canopy, GFC pass-through tent, full kitchen.
The ultimate shop truck — built for Baja.
The back of the truck is the part we're proudest of. A MITS Alloy half-tray / half-canopy in the mid-size truck spec — 6.5-foot tray, 1-meter canopy, stubby drop-down sideboards, headboard water tank, fenders sized to the 35s, an under-tray pull-out drawer that doubles as a kitchen prep table, plus a dedicated under-tray box for the ARB Twin compressor and a second box for engine fluids. (MITS Alloy stopped exporting to North America a few years back — we're now the SoCal dealer for Summit Expedition Trucks, an American manufacturer building the same kind of tray-and-canopy platform with similar specs and direct-fit truck mounts.) On top of the canopy sits a Go Fast Campers V2 XL pass-through rooftop tent — this is one of our favorite pieces of the build. Because it's the upper half of a GFC platform camper (not a standard GFC RTT), the floor has a removable panel that lets you climb up from inside the back of the canopy without going outside. We built custom canvas walls that zip down off the canopy edge to enclose the back deck, so in bad weather you can stand inside the canopy area, change out of wet wetsuits, and pass through up into the tent without ever stepping out. Twin full-size spares ride on custom mounts at the back of the tent, an ARB awning sits on the driver side, and a MITS Alloy ladder swings down from the rear when we want a quick standalone tent setup.
Inside the canopy is the kitchen and the power system. The kitchen has a 12-volt camp oven (cookies on the beach in Baja are a real thing), a 1,500-watt induction cooktop, a Nespresso machine, a slide-out vertical pantry, and a pots-and-pans drawer — all built in-house in aluminum because MITS doesn't build a North-American-spec internal fitout and we wanted to spec it our way. The fridge is an ARB Elements outdoor-rated unit with a keypad lock on the back deck. The power system is a REDARC RedVision setup centered on a 300 Ah ReliOn lithium house battery, a Manager 30 charger, a BCDC 1225 DC-to-DC charger, a 3,000-watt RedArc inverter, three RedVision screens (cab, kitchen, rear), and a 240-watt RedArc folding solar blanket — no roof solar because the surfboards live up there. A DC Power 270-amp alternator with a Big-3 wire upgrade keeps that bank charged on the move. The cab side has its own dual-battery setup (twin AGMs from Off-Grid Engineering with another BCDC 1225 and a REDARC SBI isolator for self-jump), a Switch-Pros 9100 controlling lighting, a Kenwood TM-D710 ham, an iPad Mini for nav, and the original RedVision screen up top. Out front, an ARB bumper (a modified 2nd gen Tacoma unit — there isn't much made for 1st gen Tundras, so the build is full of adapt-and-make-it-fit moments), a Warn Zeon 10 winch on Master Pull synthetic line, ARB Intensity V2 driving lights, Baja Designs Squadron SAE fogs, and a Baja Designs 40-inch ONX6+ light bar across the Rhino-Rack. A 100-Series Land Cruiser snorkel with a Centri pre-cleaner because Baja dust is real. A custom 24-gallon aluminum auxiliary fuel cell under the tray adds to the factory 29-gallon tank for ~50 gallons of usable range — set up as a transfer tank so you can leave it empty when you don't need the weight.
Built to do its job. Drives where we point it, stays out as long as we want, and gets us home.
There's no perfect vehicle to travel out of. Every single one is a compromise. This 2005 Toyota Tundra is our take on the closest thing — capable off-road, comfortable on the highway, and dialed for weeks-at-a-time camp life on the back. We've had the truck a few years and rebuilt nearly every system on it. The engine, transmission, and cab are factory. Almost everything else has been changed, reinforced, swapped, or built from scratch.
The mission is Baja. Surf trips, hundreds of miles of washboard, jagged rocks, dips and whoops you don't see coming out of corners, and 1,500-2,000 pounds strapped on the back. That's a tough ask of a half-ton, so we turned this Tundra's chassis into something closer to a 1-ton. The frame is fully boxed in 3/16" steel from the front bumper back to the rear hitch and re-coated internally to keep rust out. Every suspension mounting point has been gusseted — shock towers, spindles, cam tabs, steering rack mounts. A full-float Dana 60 (custom-built by East Coast Gear Supply, 35-spline chromoly, 3/4-ton disc brakes, ARB air locker, 4.88 gears) replaces the factory Toyota rear axle, mostly because we got tired of blowing up rear ends in the middle of nowhere. The braking system is a Powerbrake big brake kit with a Toyota T100 master cylinder and booster up front to push the bigger brakes properly, plus 3/4-ton discs out back, braided lines all around, and a Wilwood proportioning valve to dial the bias because the rear wants to lock up on a heavy build like this. We ran an FJ Cruiser transfer case with a twin-stick mod for true 2-Hi/2-Lo/4-Hi/4-Lo control, and the front end runs a factory Toyota differential with 4.88s, an ARB air locker, and high-angle CVJ inner/outer boots — we deliberately kept the factory steel axle shafts up front so they're the fuse if we get too aggressive on wheel speed. A spare CV lives in the back drawer.
Suspension is a matched Arizona Desert Racing 2.5-inch coilover and rear shock package, both with remote reservoirs and compression adjusters, on 700-pound front coils and a custom Alcan leaf pack out back built for 3 inches of lift and 2,500 pounds over stock. Specialty Control hydraulic bump stops at every corner with limit straps. SPC adjustable upper control arms paired with Solo Motorsports stock-length lower control arms (with the lower ball joint pushed forward 1 inch) shift the spindle ahead just enough to clear the 35-inch tires without needing a wider track. A Currie Antirock rear sway bar and Archive Garage Hammer Hangers and shackles tame the leaf-pack jitters on washboard. Wheels are custom 17x7.5 BRAID forged with simulated beadlock rings, machined to a 108 mm hub bore so they index correctly to the Dana 60 (Toyota 6-lug pattern, but the bore got opened up for the swap), wrapped in 35x12.50R17 BFG KM3 mud-terrains. Inch-and-a-quarter Borah front wheel spacers (custom-bored to the 108 mm bore) center the wheels on the front hubs.
Build Sheet
The full spec — vehicle, frame, driveline, suspension, brakes, wheels, armor, lighting, tray, canopy, tent, power, kitchen, fuel, water, and air.
The Vehicle
- 2005 Toyota Tundra · 1st Gen Access Cab, Limited, 4WD
- Factory 4.7L 2UZ-FE V8 · 5-speed automatic — engine, trans, and cab unmodified
- ~135,000 miles at the time of the YouTube walkthrough
Driveline & 4WD
- FJ Cruiser transfer case · twin-stick modification — true 2-Hi, 2-Lo, 4-Hi, 4-Lo
- Custom Oceanside Driveline rear driveshaft · sized for the Dana 60 swap
- CVJ high-angle front CV axles · factory Toyota steel inner shafts kept as the front-end fuse, with high-angle inner/outer boots for the lift
- Factory Toyota front differential · 4.88 gears, ARB air locker, ECGS needle bearing delete
- East Coast Gear Supply custom Dana 60 rear axle · 67" wheel-mounting-surface, 35-spline chromoly shafts, full-float hubs, 3/4-ton disc brakes, 4.88 gears, ARB air locker, ARB diff cover, Toyota 6-lug pattern
- Crown Performance braided stainless ARB locker air lines
- GPS wheel-speed sensor sending unit · for accurate speedo with the new gears + tires
Frame & Armor
- Fully boxed frame · 3/16" steel plate from the front bumper back to the rear hitch, internally re-coated for rust prevention
- Gusseted suspension mounting points · shock towers, spindles, cam tabs, steering rack mounts
- Additional rear cross-member · above the rear axle, mounting bump stops and limit straps
- Modified ARB Tacoma front bumper · adapted to the Tundra (no off-the-shelf 1st gen Tundra ARB bumper exists)
- White Knuckle Off-Road rock sliders
- Custom aluminum front skid plate
- Custom rear hitch · raised for clearance after the tray swap
Brakes
- Powerbrake big brake kit · upgraded performance pads — machined aluminum calipers, oversized rotors, much better heat dissipation under load
- Toyota T100 master cylinder & brake booster · larger displacement to push the bigger calipers
- 3/4-ton rear disc brakes · part of the Dana 60 build
- Crown Performance braided stainless brake lines · front and rear
- Wilwood rear brake proportioning valve · adjustable, balances bias since the heavy rear with a tray will out-brake the front otherwise
Front Suspension
- Arizona Desert Racing 2.5" front coilovers · remote reservoir, compression adjusters, 700 lb front coils
- SPC adjustable upper control arms
- Solo Motorsports stock-length lower control arms · with the lower ball joint pushed forward 1 inch — combined with the SPC uppers, shifts the spindle forward to clear the 35s
- Specialty Control 1.5" travel hydraulic bump stops
- 10" front limit straps
Rear Suspension
- Arizona Desert Racing 2.5" rear shocks · remote reservoir, compression adjusters
- Custom Alcan leaf springs · 3" of lift, 2,500 lbs over stock — built for the loaded weight on long Baja trips
- Specialty Control 3" travel hydraulic bump stops
- Currie Enterprises Antirock rear sway bar
- Archive Garage Hammer Hangers and shackles · reinforced rear-leaf geometry, kills the washboard jitters
- East Coast Gear Supply Dana 60 U-bolt flip kit
- 16" rear limit straps
Wheels & Tires
- 35x12.50R17 BFGoodrich Mud-Terrain T/A KM3
- Custom 17x7.5 BRAID forged wheels · 0mm offset, 108 mm hub bore (custom-bored for the Dana 60 swap), simulated beadlock rings, anthracite finish
- Borah custom front wheel spacers · 1.25" wide, Toyota 6-lug, 108 mm centerbore — index the wheels to the front hub correctly
- APEX Designs rapid air down/up valve stems
Front Bumper, Lighting & Cab Accessories
- Warn Zeon 10 winch · on Master Pull synthetic line, with a winch electronics disconnect on top of the bumper
- ARB Intensity V2 LED driving lights · on top of the bumper
- Baja Designs Squadron SAE fog lights · in the bumper fog pockets, road-legal
- Baja Designs 40" OnX6+ light bar · driving combo lenses, mounted on the front of the Rhino-Rack
- Amber covers carried for all exterior lights · we run white standard, amber when conditions call for it
- 100-Series Land Cruiser snorkel · with Centri pre-cleaner
- Alamosa dual-band ham radio antenna
- Custom side-exit exhaust · with Magnaflow muffler
Cab Electrical
- Custom Off-Grid Engineering dual battery system · twin AGM (Group 35 Full Throttle) under the hood
- REDARC BCDC 1225 DC-to-DC charger · cab-side
- REDARC SBI isolator · for self-jump from the secondary battery
- DC Power 270A alternator · with Big-3 wire upgrade — keeps both battery banks charged on the move
- Switch-Pros 9100 · 8-circuit accessory controller
- Kenwood TM-D710 dual-band ham radio
- iPad Mini · nav, music, backup-camera display
- REDARC Tow-Pro · trailer brake controller
- REDARC RedVision cab screen · tied into the canopy power system for remote on/off and battery status
Tray & Canopy (MITS Alloy)
- MITS Alloy mid-size 6.5' tray · 1870×2050×850 mm
- MITS Alloy 1-meter canopy · 1870×1000×850 mm — half tray, half canopy
- MITS Alloy stubby drop-down sideboards
- MITS Alloy 30L headboard water tank
- MITS Alloy fenders & under-tray toolboxes · sized for the 35s
- MITS Alloy ladder rack
- MITS Alloy under-tray pull-out drawer · doubles as a kitchen prep table
- MITS Alloy rear ladder · drop-down for tent access
- Custom rear canvas walls · zip down off the canopy edge to enclose the back deck for bad weather and wet-wetsuit changes
- Custom twin full-size spare tire mounts
- Custom interior fitout · single drawer with slide-out table, vertical pull-out pantry, battery cover, oven mount — all built in-house in aluminum
- L-track tie-downs · throughout the tray and canopy
- MITS Alloy paused export to North America in 2023. We now build equivalent tray-and-canopy platforms using Summit Expedition Trucks (SET) — same kind of system, US-made, direct-fit mounts for most modern trucks. See our SET builds.
Rooftop Tent & Awning
- Go Fast Campers V2 XL pass-through rooftop tent · the upper half of a GFC platform camper, with a removable floor panel that lets you pass up from inside the canopy without going outside
- Turbonap mattress · upgraded from the GFC stock pad
- ARB Touring Awning · driver side
- GFC Beef Bars · pair, mounted across the tent for rooftop tie-down
- SHITCO awning brackets · on the back of the tent fly — pulls the fly out for shade or rain coverage
- Baja Designs RTL-M 3rd brake light · running, brake, and reverse on the back of the canopy
- Rhino-Rack · shortened to clear the GFC tent, with custom backbones for 1st gen Tundra fitment
Camp Power System
- REDARC RedVision system · Manager 30 + RedVision controller, three screens (cab, kitchen, rear)
- REDARC BCDC 1225 DC-to-DC charger · canopy-side
- REDARC 3,000W pure-sine inverter · powers all 110V outlets across the rig
- ReliOn 300 Ah low-temp lithium house battery
- REDARC 240W folding solar blanket · stowed in the rear drawer; deploys when parked (no roof solar — surfboards live up there)
- REDARC water tank level sensors
- Multiple 110V, USB, USB-C, Anderson SB50, and 12V outlets · interior and exterior, both sides of the tray
- Hardkorr dimmable color-shift lights · one on each canopy door (passenger and driver side)
- Baja Designs interior rock light
- Baja Designs S1 · cargo light on the rear deck
Kitchen
- 12V camp oven · for the cookies-on-the-beach mission
- 1,500W induction cooktop · stowed; deploys quickly for short-stay meals
- Nespresso espresso machine
- Slide-out vertical pantry · custom in-house build
- Pots-and-pans drawer · custom in-house build
- ARB Elements outdoor-rated fridge/freezer · with keypad lock
- Pull-out kitchen prep table · integrated with the under-tray drawer on the kitchen side
Aux Fuel, Water & On-Board Air
- Custom 24-gallon aluminum auxiliary fuel cell · under the tray, plumbed as a transfer tank — pump it into the 29-gallon factory tank as needed; ~53 gallons total usable
- 30L headboard water tank · gravity-fed spigot on the kitchen side
- ARB Twin-Motor on-board air compressor · in an under-tray box with both ARB locker manifolds
- Air hoses, air chuck, recovery accessories · stowed in the same box
Want one like this?
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Most of what's on this build sheet can be replicated on your truck. Tell us the rig and we'll talk through how to do it.