Jeep Wrangler Build for Two Years Around Africa

The build of my Jeep is extensive, with each modification carefully thought out and planned. The build focused around primary goals, I will lay out the rationale and decisions for each.
Weight was a primary consideration for each modification, as was limited interior space.

Goal 1: Strong 4×4, big enough to sleep in, fit inside a 20 foot container.

• 2011 Jeep JK Wrangler Unlimited Rubicon.
• 3.8l V6 Gasoline engine, 6 speed manual transmission.
• Locking front and rear differentials, electronic sway bar disconnect.
• 4.10 axle ratios.
• 4:1 transfer case ratio.

Goal 2: Extremely capable off-road

Two years around Africa, especially West Africa, requires a very strong 4×4 vehicle. I chose the Rubicon for the factory diff locks, stronger D44 front axle, and low range transfer case. In addition to that, I have added:

• Suspension: Stronger and improved handling with mild lift
  • American Expedition Vehicles (AEV) 2.5″ lift with Geometry Correction Brackets.

• Bumpers: Radiator protection, stronger
  • AEV Front with Skid Plate, AEV Rear, Tire carrier and High Lift Mount.

• Tires: All-round performance, extremely durable, mild clearance increase
  • .

• Wheels: Extremely strong
  • .
  • See my rationale for the wheels and tires: Tire Selection

• Recovery: Going solo for two years, I need to be able to get myself unstuck.
  • (synthetic rope to reduce weight).
  • .
  • .
  • .
  • .
  • .
  • to remove trees and limbs if needed.

• Lighting: Inside and out, being able to see is a must
  • .
  • .
  • .
  • .
  • 2 x .
  • 2 x .

• Snorkel:
  • AEV with Pre-Filter for extreme dust removal.
  • .

• Engine Skid:
  • .

Goal 3: Interior living space

A two year expedition is not a vacation, this is my life. Given that I’m building my Jeep into a house on wheels, I want interior living space – to be able to escape the bugs, the rain, or even just escape the world for an evening will help keep me sane enough to continue.

The build and design is centered around a Pop up roof and interior cabinets I designed and built.

The roof is lighter and more aerodynamic than a roof rack + Roof Top Tent combination.

• Pop-up Camper Roof:
  • Ursa Minor Vehicles J30 popup camper, customized open rear area.
  • Read more about my modifications to it here: Ursa Minor J30 Popup Camper

• Interior: allows for standing, sitting and sleeping in the rear of the Jeep
  • Removed back seat & carpet, custom built cabinets for camper setup using:
  • .
  • .
  • To see photos and the build process of the interior see: Jeep Build Phase 1 Complete

Goal 4: Improved Sleeping, Cooking, Eating

Two years from Alaska to Argentina on my previous expedition taught me a lot.  I love camping, though after two years I was done with Ramen noodles and tinned soup. I want to eat vegetables, cheese and meat. I want to sleep up off the ground out of the mud. With that in mind, the following modifications where made:

• Fridge:
  • .
  • .

• Kitchen & Cooking:
  • .
  • .
  • .
  • For that morning cup.
  • Outback Adventure Products Trailgator.
  • See the full DIY Tailgate Table Utensil/Tool Organizer article

• Awning: Sun shade over the kitchen area at the rear
  • mounted on rear.

• Shower: Keep it simple, keep it light
  • I hang in the sun for heat.

• Fan for sleeping: Light, charges off USB, has speed settings and internal battery

Goal 5: Ability to be self-contained for weeks at a time

My aim to to get far off the beaten path, so I need to be able to support myself. With that in mind, I added:

• Water System: Water is the number one limiter for days without resupply
  • 12 gallon Drinking Water Tank Mounted Under Body.
  • .
  • .
  • See the full DIY 4×4 Drinking Water Tank, Pump and Filtation System article.

• Batteries: Isolated batteries mean I can run the fridge for days without starting the engine
  • Dual .
  • Isolated with .
  • Mounted in Nemesis Industries Dual Battery Tray.

• Solar: To charge the second battery
  • 2 x .
  • .

• Additional Gasoline: A range above 500 miles is a must
  • . (Total Range ~600mi.).
  • .

• On Board Air Compressor & Tire Repair: self-repair is a must
  • .
  • .
  • .
  • Spare values, stems, inners, etc.

Goal 6: Secure Storage for all my stuff

The stock Jeep glovebox and console are just plastic, and the hood does not lock. I improved that with the following:

• Secure Storage:
  • .
  • .

• Additional Locks:
  • .
  • .
  • .

Miscellaneous Other Modifications and gear

• Navigation: I drove AK-Argentina without a GPS. I’m not doing that again.
  • .
  • .
  • Tracks4Africa Map Pack.
  • Open Street Maps (free and fantastic!)
  • Michelin paper maps , ,  .

• Electrical: I don’t like inverters – they are inefficient, heavy and hot.
  • .
  • .
  • .
  • .
  • .

• Tools & Spares: Just the essentials.
  • for diagnosis.
  • to clean and oil air filter.
  • and tons of old wires.
  • is much better than duct tape.
  • for electrical diagnosis.
  • 1/2″ drive.
  • Tons of standard stuff – sockets, allen keys, torx bits, screwdrivers, wrenches, hammer, pliers, cutters, saw, wire, solder, etc.

• Camping / Other: Stuff to make life on the road more enjoyable.
  • .
  • .

• Camera Gear:
  • .
  • .
  • .
  • .
  • .
  • .
  • .

With that, my house on wheels is complete.

-Dan