Isuzu Vehicross Overland Build: How James and Molly Turned a 2001 Vehicross Into a Adventure Rig

This 2001 Isuzu Vehicross is one couple’s do-anything rig

More than 20 years of off-road wheeling around the Pacific Northwest has brought James and Molly Tester to their 2001 Isuzu Vehicross. Parents to four daughters who decided to kick the fun into 4WD when their children were young, they are now empty nesters who spend their free time exploring the unknown through the PNW and beyond.

Why We Chose the Isuzu Vehicross

Built over the last two years from stock to the off-road adventurer you see here, the Vehicross has slowly transformed into the Testers’ ideal overlanding build. It’s their dedicated overland rig, and they’ve added on just about anything a camper could want.

Build Timeline & Philosophy

“We’ve owned [it] for about two years. It was stock when we purchased [it], but the build constantly evolves,” James shared.

We know all too well that the process of building a rig never truly ends once it’s started. From a bevy of exterior add-ons to custom suspension upgrades and an interior and camp setup that works perfectly for them, the Testers have put in the work to make their dream rig a reality.

Over the years, the Testers have been driven by a desire not only to get outdoors, but to bring the family along for the ride.

James and Molly decided, “the best way to explore with little ones was with a 4WD.” It was around that time that Isuzu introduced the Vehicross to the market.

James recalls, “I thought they were the weirdest, coolest, most oddball thing ever,” noting, “I dig weird and cool.”

Quirks and Capabilities That Stand Out

So, what does James appreciate most about the Vehicross? For starters, its compact footprint means tight turns and tricky trails are tackled with ease, thanks to an impressively nimble turning radius and distinctive stance. Rugged approach and departure angles let them nose into unexplored corners of the PNW without flinching.

Then there’s the fun factor: nothing draws more double-takes at a trailhead. The Vehicross often sparks curiosity and friendly conversations—especially whenever a mechanic peers under the hood and inevitably asks, “Wait, what kind of Isuzu is this?” If you’re drawn to the unconventional and love a little attention, this rig won’t disappoint.

Tackling the Mods: Challenges along the Way

Of course, transforming a stock rig into a true overlander rarely comes without a few headaches. For James, the trickiest hurdle cropped up during the suspension swap.

Wrestling stubborn parts off a battered Isuzu Amigo donor wasn’t exactly a walk in the park.

Extracting components from wrecked vehicles is always a test of patience, especially when bolts don’t want to budge and rust has made a permanent home.

But with some elbow grease and a little creativity, the suspension made its way onto the Vehicross—just one of many small victories in the overall journey.

 As Unique as It Looks

With help from lifelong best friend Jamie Davis, who offered rig-building knowledge as well as experience overlanding with little ones, the Testers got started.

It was 1997 and the Vehicross had just been released. However, it wasn’t quite the vehicle on James’ mind… yet.

“When we started out,” James explains, “I couldn’t afford an FJ60 like I wanted, so we bought an Isuzu Trooper… Fast forward 20 years and 20+ Isuzus later, and I found [the Vehicross] locally for a great price from a fellow Isuzu enthusiast.”

That first Trooper that got the ball rolling sparked an interest and love for the whole Isuzu family.

Over the past 20 years, they’ve spent tons of time exploring the PNW with kids in tow, but now that their daughters are all grown up, James and Molly have taken the adventure plans into their own hands.

Family, Furry Friends, and Adventure-Ready

For the Testers, the Vehicross isn’t just a means to tackle dirt roads and rocky switchbacks—it’s the vessel for both family memories and new chapters of exploration.

When their daughters were young, James and Molly prioritized gear and modifications that would make outdoor journeys enjoyable (and safe) for four kids, proving that adventure needn’t be sacrificed for family togetherness.

Their philosophy: If you’re going off the beaten track, make sure everyone—including kids—can enjoy the ride.

As their family dynamic evolved, so did their travels. Now, with grown daughters charting their own courses, the Testers have leaned into a more spontaneous style of overlanding, still making room for their four-legged copilot, Annie the miniature schnauzer.

From lush forest trails in the Pacific Northwest to far-flung desert escapes like Moab and the Mojave, their Vehicross adapts to every landscape. An ever-evolving camp setup—with essentials from REI and rooftop tents to keep things cozy—accommodates long journeys and sudden changes in weather.

What does a typical outing look like? Think meandering through winding forest tracks, pulling up to panoramic vistas for a roadside meal, or pitching camp wherever the mood strikes. 

Annie is always along for the ride, whether she’s bounding through alpine meadows or napping on the passenger seat during a cross-country haul.

And as future plans eye everything from Mexican backroads to rallying in the Alcan 500, one thing’s for certain—the Testers’ approach is all about flexibility, comfort, and making the most of every mile with their favorite crew, human and canine alike.

PNW and Beyond

There’s almost nothing that the Testers can’t conquer in their Vehicross. Their overland adventures take them all around the country, including Moab (their go-to spot), the Mojave Desert, and more. Up next, they’re planning on heading to Mexico this fall, and, at some point, the Alcan 500, too.

Accompanied by miniature schnauzer pup Annie, the Testers are always ready to explore. While Moab has long been a go-to spot, “Anywhere there’s an adventure waiting” is good for them.

Advice for Prospective Off-Roaders

For anyone considering diving into the world of off-roading, James has some solid encouragement: Vehicles like theirs are not only easy on the wallet, but they also offer plenty of room for customization.

If you’re just starting out, you’ll find these rigs are approachable for beginners and surprisingly capable right out of the gate.

Thanks to their affordability and a wealth of aftermarket parts—think lift kits, bumpers, and accessories from brands like ARB or Old Man Emu—you can tailor your build without breaking the bank.

According to James, with a little creativity and some elbow grease, you’ll have no trouble setting up your new adventure companion to tackle everything from scenic forest tracks in the Cascades to rugged slickrock trails out in Moab.

“Dungbeetle”

James refers to their Vehicross as the “Dungbeetle.” It’s his hope that he and Molly will, “Be able to do anything in it. We’re empty nesters now, so it’s all about the adventure!”

You don’t see a rig that looks like this one out on the street every day – in fact, we hardly see any of these out there, even in the off-road world.

But that’s what James and Molly especially like about it. They’ve gone above and beyond modifying the vehicle to suit their needs, from a 1.5-inch BFR body lift to a custom suspension to a rear seat delete.

Here’s a fun fact about the Vehicross: a 1997 model was the first production Isuzu to run on external reservoir shocks.

The model was a Paris-Dakar rally vehicle, and it won. Keeping that tradition, the Testers employ a set of Old Man Emu KYB Reservoir shocks in both the front and rear of their 2001 model.

In addition, the suspension features fabricated 1.5-inch diff drop brackets in the front as well as Independent4x HD rear links. Old Man Emu 929 coils and coil keepers round out the setup on both ends.

Rough and Ready

“I believe you don’t mess with the heart of the vehicle too much to retain as much dependability as possible,” James explains.

To that end, the only change they’ve made to the Vehicross’ engine is a reusable air cleaner. A Haynes HD transmission cooler inline with the factory has a similar goal, keeping the rig’s 4l30e transmission running at its best as well.

They’ve re-geared the diffs from 4.30 to 4.56 from a Trooper, with Isuzu Corporate 12-Bolt in the rear and 10-Bolt in the front.

“The differential drop was a key piece for the vehicle in terms of reliability. It allows us to run 35-inch tires but keeps the CV angles close to neutral, thus reducing stress and fatigue on the weakest point of the drivetrain.”

That modification, combined with a Lokka locker in the front, and a soon-to-be-added ARB rear locker make all the difference in the rig’s off-road performance.

Engine and Transmission Tweaks for Dependability

James is a big believer in keeping things simple when it comes to the heart of the vehicle.

To preserve the reliability that’s gotten their Vehicross through countless adventures, they’ve kept engine changes minimal—just a reusable air filter to breathe a little easier, and a heavy- duty Haynes transmission cooler to help the 4l30e automatic handle everything from daily errands to long, winding trails.

For the drivetrain, they swapped in beefier gears—moving up from 4.30 to 4.56 ratios sourced from a Trooper.

With 12-bolt and 10-bolt diffs now in play, and a differential drop bracket keeping their CV angles happy, the stress points on the axles are kept in check even with those aggressive 35-inch tires.

Up front, a Lokka locker boosts traction, while an ARB locker for the rear is in the works for even more off-road confidence.

A major project on the horizon: saying goodbye to the somewhat lightweight stock automatic transmission. At close to 5,000 lbs.

With all the gear piled on, the Dungbeetle is no featherweight, and James has his sights set on swapping in a robust AR5 manual box.

The goal? Greater durability on punishing trails and more control for the toughest trips yet.

More Creature Comforts and Off-Road Ingenuity

To further improve drivability, James added Superwinch manual-locking front hubs. These not only soften steering but also make pavement driving more comfortable on the drivetrain—a small change that makes a big difference when transitioning between off-road adventures and daily driving.

Other modifications include HD tie rods in their steering column, made from off-the-shelf Ford and Dodge parts, as well as welded-on rock sliders adopted from a Jeep TJ.

More Additions

The Vehicross rolls on MB Wheels TKOs, which James has painted to better match the look of the rig. Wrapped in bulky Falken Wildpeak MTs, no challenge is too much, not even a steep obstacle that once had them rolling on just one wheel.

Under the hood is a vinyl-wrapped carbon fiber insert that matches the door cards; above the hood is a serious wattage-producing setup of lights.

It includes Sylvania Automotive zXE gold Halogen headlights, but they’ve also done a full LED conversion on all the rest of the rig’s exterior lights.

Two 4WheelParts HID round lights adorn the front bumper, whereas their tracer lights are what James refers to as “Amazon specials.” Hey, what works, works.

A Tailgater Tile table, Voodoo Offroad Recovery Gear kit, Silverwing Roof Top Tent, Roam Adventure Co. Awning, and All-Top 4×4 Spare Tire Trash bag form the base for their camp setup wherever they go.

Interior Setup

In place of the rear seat, the Vehicross has a custom storage box that keeps all of the Testers’ gear organized.

Up on the dash, James runs the OnX Offroad app through Android Auto on his Boss audio system. Additionally, they use Midland Radio MXT 575 GMRS as well as bringing along Baofeng handhelds, “for backup.” An Optima Red Cell battery and GoalZero power stations round out their interior setup.

One last sneaky addition is a Kartisen car ceiling cargo net, “for snacks,” of course, and other easy-to-access small items.

Manual Swap and More

One major change on the docket for the Dungbeetle Vehicross is a swap to a manual transmission.

According to James, “The 4l30e transmission that Isuzu used from GM was never designed to be on a heavy 4×4 vehicle.”

And the Vehicross is certainly one heavy vehicle – about 4,200 lbs. stock, the Testers’ rig weighs in closer to 5,000 lbs. thanks to add-ons like a rooftop tent and hefty rubber.

“By adding the AR5 transmission, we will take out the undersized transmission and replace it with a robust manual upgrade,” he explains.

“This will enable us to really push the limits of the vehicle and ourselves for even longer, tougher adventures!”

Plus, if you’ve kept an eye on their Instagram, you’ll see that the family just welcomed the Dungbeetle’s baby sister, another Vehicross that’s undergoing a transformation in their garage.  Keep up with James and Molly Tester’s adventures in their Vehicross on Instagram with #DUNGBEETLE_VX and all their auto fun @dungbeetle_vx.

Daily Driver Duties

Despite all the modifications and beefed-up capability, the Dungbeetle isn’t just a weekend warrior—it pulls daily duty.

From school drop-offs to grocery runs and everything in between, the Testers’ Vehicross is very much a road-going companion Monday through Friday, before transforming into an off-road escape rig whenever adventure calls.

Whether it’s crawling up rocky paths or navigating rush hour, this lifted Isuzu handles both worlds with ease—making every day just a little bit more exciting.

UPGRADES

2001 Isuzu Vehicross

Engine: Factory Isuzu 3.5L v6

Suspension: Isuzu custom front suspension with 1.5-inch differential drop brackets and Old Man Emu KYB reservoir shocks; Isuzu 3-Link rear suspension with Old Man Emu KYB reservoir shocks; Independent4x HD rear links; Old Man Emu 929 coils, coil keepers

Wheels & Tires: 16×8 MB Wheels, 3-inch backspacing; Falken Wildpeak MT size 315/70/16

Interior Accessories: Midland Radio MXT 575 GMRS and Baofeng handheld radios; Optima Red Cell; GoalZero power station; Kartisen Car Ceiling Cargo Net

Exterior Accessories: Hood insert vinyl-wrapped carbon fiber to match door cards; Sylvania zXE Gold Halogens; 4WheelParts HID round light bar; Amazon tracer lights; Rock sliders donated from Jeep TJ;tailgater tire table; Voodoo Offroad Recovery Gear; Silverwing Roof Top Tent, Roam Adventure Co. Awning; All-Top 4×4 Spare Tire Trash bag

Additional Modifications: Full exterior LED light conversion; 1.5-inch BRF body lift; Rear crossmember with receiver hitch

FREQUENTLY ASKED QUESTIONS

How does the Torque-On-Demand system work in the Isuzu VehiCROSS?

The Torque-On-Demand (TOD) system in the Isuzu VehiCROSS is designed to seamlessly enhance driving performance by automatically adjusting the distribution of power between the vehicle’s front and rear wheels. This advanced feature continuously monitors road and driving conditions, employing sensors to detect any changes in traction needs.

When optimal traction is required, the system intelligently shifts from directing all power to the rear wheels to an even 50/50 split between the front and rear wheels. This transition occurs in a matter of milliseconds, ensuring that the vehicle maintains stability and control across varying terrains without driver intervention.

This adaptability allows the Isuzu VehiCROSS to handle different environments—whether you’re cruising on highways or navigating off-road adventures—with efficiency and confidence. The TOD system provides a smooth transition and maximizes grip, resulting in improved handling and enhanced safety.

How does the 2001 Isuzu VehiCROSS perform off-road compared to other 4×4 vehicles?

There’s almost nothing that the Testers can’t conquer in their Vehicross. Their overland adventures take them all around the country, including Moab (their go-to spot), the Mojave Desert, and more. Up next, they’re planning on heading to Mexico this fall, and, at some point, the Alcan 500, too.

What sets the 2001 Isuzu VehiCROSS apart is its immediate readiness for off-road action. Unlike many other 4x4s that demand costly modifications before tackling rugged terrain, the VehiCROSS is good to go right off the lot.

• Cornering Capability: It handles turns with impressive stability, avoiding the leaning and rolling tendencies found in vehicles like the Jeep Wrangler. This means you can confidently hit a corner, accelerate, and feel the car hook up and propel you forward.
• Superior Articulation: The VehiCROSS boasts remarkable articulation, allowing it to navigate challenging landscapes with ease—something other 4x4s aspire to achieve.

In essence, this vehicle blends adventure-ready features with the reliability and performance needed for diverse terrains, from rocky trails to sandy deserts. The Testers’ experiences underscore its prowess, making every journey an opportunity to explore further without hesitation.

What is the engine power and performance of the 2001 Isuzu VehiCROSS?

“Engine: Factory Isuzu 3.5L v6”

The 2001 Isuzu VehiCROSS is powered by a robust 215-horsepower engine, delivering impressive performance with its 3.5-liter, direct-injection DOHC V6. This powerhouse is paired with a four-speed automatic transmission, designed with both winter and power modes to adapt to various driving conditions seamlessly.

Not just about raw power, the VehiCROSS features advanced engineering innovations. The Torque-On-Demand (TOD) four-wheel-drive system stands out, dynamically adjusting the torque balance between the front and rear wheels. This system can shift from 100-percent rear drive to a balanced 50/50 four-wheel drive in milliseconds, ensuring optimal traction and control.

Complementing the TOD system are a limited-slip differential and four-wheel ABS, enhancing stability and safety. These features collectively ensure that the VehiCROSS is not only powerful but also versatile, ready to tackle diverse terrains with confidence.

What are some practical concerns related to the vehicle’s interior and visibility?

Potential buyers should be aware of the practical issues such as the limited space within the interior, which could be uncomfortable for passengers, and the restricted visibility that might pose challenges during driving.

How does the styling of the vehicle affect its appeal?

The vehicle’s distinctive design is a double-edged sword; while it sets the VehiCROSS apart and appeals to those seeking something unique, it may not be attractive to all potential buyers due to its unconventional appearance.

What are the main disadvantages of the 2001 Isuzu VehiCROSS?

Some drawbacks of the VehiCROSS include its unconventional styling, which might not suit everyone’s preferences. Additionally, the vehicle’s interior is somewhat cramped, and there are concerns regarding limited visibility.

What is the seating capacity and interior space like in the 2001 Isuzu VehiCROSS?

In place of the rear seat, the Vehicross has a custom storage box that keeps all of the Testers’ gear organized. This innovative design choice speaks to the vehicle’s versatile interior.

While the custom storage box maximizes utility, the VehiCROSS comfortably seats two in the front, providing a cozy sports car atmosphere.

The interior is thoughtfully designed with red and black leather-trimmed seating, ensuring both comfort and style for the driver and passenger.

This combination of practicality and aesthetics makes the VehiCROSS a standout option for those who value both form and function in their ride.

What engine and transmission did the Isuzu VehiCross use?

The Isuzu VehiCross featured a 3.5-liter V6 engine under its distinctive exterior, delivering 215 horsepower and generating 230 lb-ft of torque. It was paired with a four-speed automatic transmission originating from GM, although this transmission wasn’t highly regarded by enthusiasts of the brand.