Building a Budget Adventure Rig
If you read the Part 1 of this series, you know that we set out to make a 2021 Dynamax Isata 5 with the Explorer Package and factory 4×4 an Adventure Rig we can truly enjoy on a somewhat “everyman” budget. Our goal was to do all of this for a grand total of less than $150,000. Let’s see how we did.
After buying the from La Mesa RV in Port St. Lucie, Florida for $129,740 with just 22,000 miles on the clock, we immediately reached out to the team at Buckstop Truckware to complete the transformation. To remind you of what this rig looked like when we bought it, here it was on delivery day at La Mesa. While we chose this particular unit from Dynamax as it had many great features already, we were getting ready to take it to the next level.
Enter the team at Buckstop. After a discussion with Dusty, we came up with a game plan to utilize their Legacy Single Wheel Conversion Kit which came in at $20,000 total bringing us in just under the $150,000 goal. When we delivered the vehicle to Buckstop’s Oregon location, we couldn’t be more blown away. Dusty took me on a tour and this is truly a start to finish, Made in the USA fabrication shop. I have taken some pictures to bring you along on the tour, but from wheel blanks, tube steel and plate steel, they make this kit come to life. Check out some of these pictures below:
Here is an overview of what you get with the Buckstop Legacy Single Wheel Conversion Kit
Buckstop Legacy Single Wheel Conversion Kit
The Buckstop Legacy Single Wheel Conversion Kit—often called a “super single” conversion—transforms dual-rear-wheel (DRW) trucks into single-wheel setups designed for both strength and versatility. It’s a fully engineered system that brings together all the parts, geometry corrections, and aesthetic elements needed to make the conversion seamless. The goal is simple: preserve heavy-duty load capacity while dramatically improving off-road traction, ride quality, and overall drivability.
Key Features
All-in-one engineered system
Buckstop’s conversion kit provides every component needed to complete the transformation from dual to single wheels—no hunting for miscellaneous parts or mixing brands. Every element has been designed to work together as a system, ensuring consistent performance, load balance, and long-term reliability.
Suspension and geometry corrections
A significant part of the conversion involves properly adjusting suspension geometry to handle larger tires and the wider track. The kit includes new coil springs, radius arms, and a heavy-duty track bar mount fabricated from thick steel plate. These parts maintain steering precision and stability while delivering a softer, more compliant ride. The system typically adds around 3.5 inches of lift under full load, optimizing both ground clearance and suspension travel.
Body and fender modifications
To accommodate the wider tires, Buckstop includes custom 8-inch-wide fender flares with an integrated inner liner. These are engineered for both appearance and practicality, protecting the bodywork from debris while giving the truck a muscular, factory-finished look. A replacement structural panel behind the headlight area provides additional clearance without the need for welding or frame cutting, keeping the installation as straightforward as possible.
Heavy-duty wheel and tire setup
At the core of the system are the forged aluminum 20×11 wheels, made in the USA and rated at over 7,000 pounds each. The wheels are designed to be reversible—mounted “dished in” for the front and “dished out” for the rear—eliminating the need for separate wheels or spacers. Tires typically measure 335/80R20 (approximately 41 inches in diameter), offering a substantial footprint that’s ideal for carrying heavy loads over variable terrain.
Purpose-built bumper and accessories
To match the truck’s new stance, the kit includes an extra-wide heavy-duty winch bumper. Optional accessories such as extended running boards and underbody skid pans are available to further enhance off-road protection and accessibility. The result is a cohesive package that looks as good as it performs.
Proven engineering and load testing
Each kit is extensively tested under real-world conditions. Buckstop has loaded chassis with 10,000 pounds and subjected them to full-articulation tests to confirm proper suspension travel, clearance, and stability. This ensures that the conversion retains full function and durability even under extreme conditions.
Benefits
Superior off-road traction
Traditional dual-rear-wheel setups excel on pavement but struggle in soft terrain. Two narrow, high-pressure tires on each side tend to dig into sand, mud, or snow, leading to traction loss. The Buckstop conversion replaces them with a single, wide tire that distributes weight more effectively and can be aired down for added grip. The result is a truck that performs confidently on loose or uneven surfaces without sacrificing payload capacity.
Maintains heavy-duty load capacityDespite the shift from duals to singles, these kits are designed for trucks in the 15,000- to 22,000-pound GVW range. The tires’ load ratings—typically between 6,700 and 7,000 pounds per tire—allow the truck to carry nearly the same weight as before, making it suitable for commercial, emergency, or expedition use.
Simplified maintenance and longer tire life
By eliminating inner duals, there are fewer tires to manage and rotate. The reversible wheel design also allows front and rear tire rotation for more even wear. This makes inspections, balancing, and replacements simpler while improving long-term maintenance efficiency.
Improved handling and ride comfort
The combination of redesigned suspension components and larger, more compliant tires produces a noticeably smoother ride, particularly on rough or uneven roads. Steering response remains tight and predictable, with reduced body roll and improved road feel. The kit’s geometry corrections ensure that alignment and tracking remain consistent under load.
Enhanced clearance and rugged appearance
The 8-inch fender flares and wider stance give the vehicle a bold, functional look that communicates strength and capability. The higher ride height increases ground clearance, improving approach, breakover, and departure angles. The heavy-duty bumper and optional accessories complete the transformation into a visually and mechanically cohesive setup.
Customizable for any mission
Whether you’re building an off-road camper, a fire or rescue truck, or a heavy-duty utility vehicle, the Buckstop system adapts easily to your application. Optional upgrades like skid plates, lighting mounts, and step systems let you fine-tune the truck for your operational environment.
Real-World Applications
This conversion is particularly valuable for vehicles that need to perform both on the highway and in soft terrain. Dually trucks often sink or spin when used off-road, especially when loaded. The Buckstop kit eliminates that weakness while maintaining commercial-grade durability. Fire departments, overland builders, and fleet operators alike can benefit from the improved stability, traction, and ease of maintenance.
For expedition and overland setups, the larger tire volume allows for better airing-down flexibility, increased flotation, and a smoother ride over rough tracks. For fire and brush trucks, it provides the ability to traverse sand, mud, or loose soil without bogging down, ensuring dependable access in critical situations.
The Buckstop Legacy Single Wheel Conversion Kit offers a complete, engineered solution for transforming a dually truck into a highly capable single-rear-wheel powerhouse. It merges rugged off-road functionality with on-road stability, maintaining heavy-duty load capacity while enhancing traction, comfort, and aesthetics. With all components—suspension, body, wheels, and bumper—designed to work together as one cohesive system, this kit delivers a professional, durable, and performance-focused result.
Whether you’re tackling rugged terrain, carrying critical equipment, or building the ultimate expedition rig, Buckstop’s single wheel conversion sets a new standard for capability and confidence on any surface.
So, How Did It Turn Out?
We couldn’t be happier with the new capability of the Dynamax with this kit. What blew us away the most was the ride quality and fuel mileage. We expected a rougher ride and the fuel mileage to go off the cliff. The reality is that the ride quality actually improved and we only lost about .75 miles / gallon.
Some Final Touches
Baja Designs Lights
After this conversion, we wanted put the cherry on top, so we reached out to our friends at Baja Designs for lighting. We added some Squadron-R SAE, Pair LED Spot in Amber, XL-R 80, Pair Driving/Combo and LP9 Pro, LED, Driving/Combo mounted to the bumper using Axia Alloy mounts.
The LP9 Pros are the focal point and they are an industry leading light. These are inspired by the legendary 8-inch La Paz HID, the Baja Designs LP9 brings that heritage into the modern era with advanced LED performance and sleek styling. Featuring nine forward-projecting LEDs and six for Integrated Peripheral Technology (IPT), the LP9 delivers an impressive 12,547 lumens at 9 amps. The IPT system provides a 200-degree spread of usable light, ensuring exceptional visibility on and off the trail.
To maintain peak performance, Baja Designs engineered the LP9 with Direct Ducted Cooling (DDC) — a unique airflow system that channels air from the front of the housing across the rear heat sinks for superior thermal management. Combined with its daytime running light, low beam, and high beam modes, the LP9 offers unmatched versatility in a single package.
The LP9 Pro is available in multiple beam patterns to match different driving needs. The driving/combo pattern blends 42-degree driving optics with an 8-degree spot for balanced near- and far-field illumination (Lighting Zones 1–3). For maximum distance, the spot pattern focuses a tight 8-degree beam ideal for long-range visibility (Zones 4 & 5) and pairs perfectly with wide cornering or combo lights. The result is a powerful, purpose-built lighting solution ready for any terrain or condition.
Warn Winch
We also decided to add a Warn Winch to give us a helping hand when needed. For a rig this big, a standard winch wouldn’t do. We went with a 16.5TI-S Heavyweight Winch. This winch is engineered for the toughest recovery situations, the WARN 16.5ti-s is the most powerful truck winch in the lineup, delivering an incredible 16,500 pounds of pulling capacity. Built for the biggest and heaviest vehicles, it combines brute strength with advanced technology to ensure reliable performance in any condition—on or off the pavement.
This premium winch comes equipped with 80 feet of 3/8-inch Spydura® Pro synthetic rope, a lightweight, easy-to-handle line that offers exceptional strength and durability. The rope’s heat-treated fibers deliver maximum tensile strength, while a temperature-resistant sleeve on the first layer protects against heat buildup during demanding pulls.
A thermometric indicator LED provides real-time feedback to the operator, helping monitor motor temperature for safe and efficient winching. Inside, a series-wound motor powers a smooth three-stage planetary gear train, delivering efficient and consistent pulling power. The best-in-class cone brake ensures superior load control, while the large-frame winch design with feet-forward mounting adds durability and stability.
Rounding out the package are an 18,000 lb EPIC hook, contactor control for reliable electronics, and WARN’s Limited Lifetime Mechanical and Seven-Year Electrical Warranty. The 16.5ti-s stands as the ultimate choice for heavy-duty recovery—where performance, safety, and power are non-negotiable.
