Why Go All-In on a USA-Built Overland 4Runner?
If you’re building a Overland-Ready 4Runner, you’re not just upgrading parts — you’re investing in self-reliance. Whether you’re crossing the Rockies, desert-tripping in Baja, or chasing sunsets through Utah’s slickrock, every bolt-on matters.
When you choose USA-made components, you’re getting:
- Battle-tested gear built for North American terrain
- Higher quality standards from trusted manufacturers
- Fast access to support, parts, and warranty service
- Products made by people who wheel, not just weld
In this guide, we’ll walk you through exactly how to build an overland-ready 4Runner using only USA-made parts, with special emphasis on Westcott Designs
gear. From roof storage to recovery and ride comfort, this build is designed to go the distance — and look great doing it.
gear. From roof storage to recovery and ride comfort, this build is designed to go the distance — and look great doing it.
Step 1: Start at the Top with a Modular Roof Rack
No overland rig is complete without a robust roof rack system — especially if you’re hauling extra water, fuel, rooftop tents, recovery boards, or camera gear.
Our Pick: Westcott Designs Full-Length Modular Roof Rack- Made in Arizona using precision-cut aluminum
- Modular crossbar system allows flexible loadouts
- Integrated light bar mount for trail lighting
- Optional Molle panels for mounting tools and gear
- Low-profile aerodynamic design reduces drag and noise
- No-drill install on 6th Gen 4Runners
This rack is the foundation of your overland build. Whether you’re going minimalist or loading for a week-long expedition, Westcott’s modular platform has the strength and modularity to evolve with your trips.
Shop Roof Racks →Step 2: Add Frame-Mounted Rock Sliders
Rock sliders protect your 4Runner’s body from trail rash, boulders, and tight switchbacks — and in overlanding, that means peace of mind on technical routes.
Westcott Designs Rock Sliders- Frame-mounted bolt-on design for serious strength
- DOM tubing construction = superior impact resistance
- Optional kick-out for deflecting trees and rocks
- Dual-use design acts as both protection and step access
- Powder-coated and trail-tested across the Southwest
Add these before your first remote trail and never worry about body damage again. They’re one of the most cost-effective insurance policies you can install on your rig.
Shop Rock Sliders →Step 3: Dial In Suspension Without Sacrificing Ride Quality
Most overland routes combine paved road miles, washboard forest roads, and light-to-moderate trail crawling. You want lift and load-handling — without harsh ride penalties.
Westcott Designs Preload Collar Lift Kit- Retains factory shocks for OEM ride comfort
- Lifts front and rear evenly to eliminate rake
- Supports additional roof or rear cargo weight
- Quick install with no cutting or welding
This lift kit is ideal for 4Runner owners who want improved off-road clearance without compromising daily driveability. Bonus: it keeps your factory KDSS or XREAS systems intact.
Step 4: Optimize Storage with Molle Panels and Gear Mounts
Organization is essential for long-haul travel. Molle panel systems let you mount everything from axes and first aid to radios and toolkits — all within arm’s reach.
Westcott Molle Panel System- Laser-cut aluminum panels for durability and light weight
- Custom fit for 4Runner roof rack, tailgate, and interior
- Compatible with off-road tool pouches and quick-release mounts
- Helps prevent gear shifting or clutter during trail rides
Combine exterior and interior panels to keep your essentials tight and secure, no matter the terrain.
Step 5: Add USA-Made Lighting for Night Navigation
Lighting isn’t just for style — it’s a safety necessity. Whether you’re navigating camp after dark or spotting a tricky rock garden at 2 MPH, you’ll want a reliable, American-made setup.
Trusted USA-Made Lighting Brands:
- Baja Designs – Trail lights, pods, and S8 light bars
- KC HiLiTES – Gravity Pro systems and amber fog lights
- Rigid Industries – Scene lights and ditch light kits
Pair them with Westcott’s integrated rack cutouts or add hood-mount brackets to keep everything clean and compact.
Step 6: Build Out Recovery and Trail Essentials
Even a well-prepped 4Runner can get stuck — it’s the trail’s way of keeping us humble. A basic overland recovery kit should include:
- Recovery boards (MAXTRAX or ActionTrax – made in the USA)
- Soft shackles and kinetic ropes (Factor 55 or GearAmerica)
- Compressor and tire deflator (ARB USA or MORRFlate)
- High-lift jack with Westcott-compatible rack mount
- USA-made shovel or spade mounted via Molle
Westcott’s roof rack and Molle panels allow multiple secure mounting options — keeping your tools handy when time matters most.
Step 7: Choose USA-Made Cargo Solutions
The interior of your 4Runner needs to be just as efficient as the outside. For overlanding, look for American-built solutions that make the most of your cargo space:
- Goose Gear or Rago Fabrication drawer systems
- Blue Ridge Overland Gear pouches & organizers
- Westcott Molle tailgate panel + interior storage platforms
Everything should have a home — and that home should be quiet, dust-free, and rattle-free.
Optional Add-Ons for Comfort and Camping
Want to turn your 4Runner into a full-blown home on wheels? Consider these USA-made accessories:
- CVT or FreeSpirit Recreation rooftop tent (American-assembled)
- 23ZERO USA awning + room enclosure
- Tembo Tusk Skottle (camp kitchen)
- Dometic or IceCo fridge/freezer (USA service and support)
Westcott’s roof rack and modular loadout system gives you the structural foundation to mount and store all of the above — no matter your travel style.
Why “USA-Made” Builds Just Work Better
Beyond the pride of supporting domestic manufacturers, there are clear technical and long-term advantages to building your overland 4Runner with American-made gear:
- Fewer fitment issues
- Better powder coating & weather resistance
- Stronger welding standards
- Local support and shorter lead times
- More thoughtful product design
Customer Story: “Everything I Needed, Nothing I Didn’t”
“When I decided to build my 6th Gen 4Runner for overlanding, I knew I didn’t want to compromise on quality. Every Westcott part I installed fit perfectly, looked clean, and made a real difference on the trail. I’ve slept on the roof, driven through Montana blizzards, and crossed the Mojave — all without a hiccup. And best of all, I did it with gear made right here in the USA.”
— Chad R., Boise, ID
Build It Once, Build It Right
Overlanding isn’t about collecting gear — it’s about preparing for what the wild throws your way. A USA-made build ensures that every piece of your 4Runner — from the sliders to the light bar — was designed by people who understand the stakes.
Westcott Designs™ is proud to be part of that build process. Our products are made in America, tested in real terrain, and designed for the long haul.
is proud to be part of that build process. Our products are made in America, tested in real terrain, and designed for the long haul.Ready to start your build?
Explore our complete lineup of USA-made accessories for the 2025 Toyota 4Runner:
Upgrade your rig?Explore our full lineup of USA-built 4Runner parts now: