The Big Rig: Building DX69, Our Ford Ranger Super Duty. Showroom to sandy tracks.

Mt Disappointment, Melbourne - Photos by Geolian

Enter DX69 – The DEXON Super Dut

Every now and then a vehicle appears that just feels like the right platform for a project. Something about the design, the capability or the potential tells you it’s worth the effort. The Super Duty had that feeling from the start. So the plan was simple: get one as early as possible, build it properly and see just how far we could push it. Fortunately our good friends over at Bayford Ford in Epping were just as excited about the idea as we were. After a few conversations and a bit of patience, they managed to allocate us one of the first cab-chassis Ranger Super Duties to land in Australia. And yes, we chose Seismic Tan.

If you know our other vehicles, that might seem slightly out of character. Our N80 Hilux (Zero.Lux) is about as dark and aggressive as a ute can look, and our 80 Series LandCruiser has spent most of its life proudly wearing white and getting fixed or upgrades. But Ford had made a bit of a song and dance about the Super Duty colour palette, and we figured if we were going to build something different, we might as well start with something that stood out. Besides, we had a feeling subtlety wasn’t going to survive the modification process anyway. A few weeks after placing the order, the truck arrived. Stock. Untouched. And surprisingly simple.

Climbing into the cab for the first time was almost refreshing. Compared to a Next-Gen Ranger or Raptor, the interior felt stripped back. Cloth seats, minimal trim and none of the flashy luxury touches that dominate modern utes. But honestly? We liked it. Our Hilux is pushing fifteen years old. Our 80 Series is nudging thirty. So the simplicity actually felt familiar. This wasn’t meant to be a luxury cruiser. It was meant to work. Once registration was sorted, DX69 was officially ready to begin its transformation.

“To be completely honest, it was not what we were expecting. Jumping behind the wheel for the first time was a little bit of a shock…”

Mt Disappointment, Melbourne - Photos by Geolian Coleiro

The First Modification – Enter TUS Offroad

Every build has that moment where the vehicle stops being stock and starts becoming something else. For DX69, that moment happened at TUS Offroad, just outside Melbourne. The team there had already begun preparing for the launch of the Super Duty and had developed a tray specifically for the platform, they called this, the DR2. Now if you’ve spent any time researching trays recently, you’ll know the market is absolutely flooded with options. Everyone claims theirs is stronger, lighter or more innovative than the rest, and choosing one can feel like trying to order coffee in Melbourne, complicated and mildly stressful. But the DR2 caught our attention for a simple reason. It looked right. Not overdesigned. Not full of unnecessary gimmicks. Just a clean, functional tray that followed the lines of the vehicle properly. The specs were solid too, 1750mm long, 1800mm wide, with trundle drawer storage, underbody toolboxes, AdBlue provisions and aircraft rails for securing gear.

Within a few hours the Super Duty had gone from bare cab-chassis to something that actually looked ready for work. Of course, the real test wasn’t how it looked in a workshop. It was how it behaved when pointed at dirt. So naturally we did the most logical thing possible. We drove straight to Mt Disappointment. There’s something reassuring about testing a brand new vehicle by immediately throwing it at hills with a name like Mt Disappointment. The result? The Super Duty climbed everything we threw at it, comfortably. The factory suspension was surprisingly impressive, and the addition of the tray didn’t upset the balance of the vehicle at all. In fact, compared to some of our older rigs, it almost felt luxurious.

But the tray was only the beginning. Because if this was going to become a proper touring rig, it needed a canopy setup that could actually support life on the road. We envisioned building the full touring setup. Back at TUS Offroad, we sat down with the team to design the canopy layout. There are thousands of ways to set up a touring ute, but we knew exactly what we wanted based on years of travelling in the Hilux. Instead of going for a full-length canopy, we chose a 1200mm TUS Offroad canopy. Why not full length?

Because having open tray space behind the cab is surprisingly useful. Firewood, muddy recovery gear, tools, or just somewhere to sit while making a coffee at camp, it’s one of those things you don’t realise you need until it’s gone. Inside the canopy we built a proper touring setup. A 2000W dual battery system with inverter provided the backbone of the power system. Excessive? Maybe. But when you’re travelling remote Australia, running out of power quickly stops being funny. Especially when your Bushman’s Upright Fridge is responsible for keeping food, and more importantly, cold beers at the correct temperature.

From there the canopy started to fill up quickly. A slimline pantry, dual slide drawers, spare jerry can storage and a spare wheel mount were installed, along with a Westinghouse induction cooktop and a small camp oven for those moments when pies and sausage rolls deserve proper cooking. Everything was neatly wired and finished to an almost factory level. TUS Offroad had absolutely nailed the execution.

Moreton Island, Queensland - Photos by Geolian

“This build became a collaboration and more of a multi brand build rather than ours. It felt like everyone was so supportive and excited to see how it would finally turn out.”

Hello Rhino-Rack. A Roof Built for Adventure

Not long after the canopy was complete, our friends at Rhino-Rack reached out to discuss the next stage of the build. Their Rhino-Rack Platform 6 roof rack system, originally designed for the Next-Gen Ranger, looked like it might also suit the Super Duty. So naturally we agreed to test it. Installation wasn’t exactly quick. The roof liner had to come out along with various interior trim pieces to access the mounting points inside the roof cavity. But a few hours later, the Platform 6 with Backbone system was mounted. And it looked like it had always belonged there. The Platform 6 is about 30% lighter than the previous system and uses Rhino-Rack’s modular accessory mounting channels, making it incredibly versatile. The first accessory to go up there? A set of Tan MAXTRAX, mounted using Rhino-Rack’s angled brackets. Then it was back to Mt Disappointment again. Because one test drive is never enough.

Giving the Super Duty Some Presence

With the rear of the vehicle sorted, attention turned to the front. Early morning drives through regional Australia tend to involve wildlife, lots of it, so front-end protection quickly became a priority. Our friends at Hamer 4x4, based in Melbourne’s east, had already begun developing a Super Duty bull bar. After a few conversations, we organised for DX69 to head to their workshop where they installed one of the first prototype bars in Australia. The fitment was perfect. The bar included integrated indicators and winch compatibility, while dramatically improving the presence of the truck. Suddenly the Super Duty looked exactly how we imagined it should. Big. Solid. And slightly intimidating.

One of the biggest questions surrounding the Ranger Super Duty was simple. Would it fit 35-inch tyres? Before answering that, we had to find wheels.

The new eight-stud hub pattern meant options in Australia were still limited, but eventually we settled on KMC Impact wheels in polished finish. Black wheels would have been the obvious choice. But obvious is boring. For tyres we chose Maxxis Razr Mud Terrains, a tyre we already trusted after running them on our Hilux for over 80,000km. Once fitted, the truck’s stance completely changed. And the answer to the big question? Yes — 35s fit.

Removing the front mud flaps allowed full steering lock, and during a recent trip to Moreton Island, we ran them at 20 PSI on soft sand without a single issue.

So the finishing touches included a few final accessories completed the build. Our mates at Pirate Camp Co in Brisbane supplied a bonnet-mounted bracket system that doubles as gas struts and antenna mounts. Perfect for installing our GME XRS UHF radio system. Inside the cabin we fitted Razorback Neoprene Premium seat covers, custom embroidered with the DEXON logo. After more than a decade of abuse in our Hilux, Razorback had already proven their durability. Finally, a few creature comforts went into the canopy for longer trips. A Nespresso machine, an iTechWorld PS1800 power station, a 300W solar blanket, and the OnTap Roam portable shower. Because even serious touring rigs deserve decent coffee and a hot shower.

Final Thoughts – Is the Ranger Super Duty Worth It?

Final Thoughts? All of this happened in roughly three months. Which, looking back on it now, is slightly ridiculous. But the result is DX69, a Super Duty build that we genuinely believe might be one of the most complete examples in the country right now. Not because it’s the biggest or the flashiest, but because every part of the build had a purpose. It was never about throwing parts at the vehicle just to say we did. It was about building something capable enough to handle whatever we pointed it at, whether that meant remote touring, long highway runs, or the occasional sand trip up north.

The Ranger Super Duty has certainly divided opinion since launch. Some people absolutely love the idea of it, the capability, the numbers on paper, the promise of a modern heavy-duty touring platform. Others are taking a more cautious approach, waiting to see how the platform performs over time and whether it can really earn its place alongside long-standing legends like the LandCruiser 70 Series. And that’s fair enough. Because the truth is, this vehicle isn’t for everyone.

For a lot of people, it’s probably overkill. It’s big, it’s heavy, it’s thirsty, and the ride is definitely firmer than the average lifestyle ute. If you don’t need the extra towing capacity or the heavier load-carrying ability, there are plenty of other options out there that will do the job just fine. But for the people who do need it or the people who regularly find themselves overloaded, under-equipped, and a long way from help, the Super Duty suddenly makes a lot of sense. Heavy caravanners. Remote-area travellers. Builders hauling serious weight.

For that crowd, this truck isn’t excessive, it’s exactly what they’ve been waiting for. And if we’re being honest, we probably fall into that group.

We’ve always been Toyota people. That runs deep in the family. Our Hilux and 80 Series have taken us across thousands of kilometres of tracks, beaches and highways, and we still love them. But after 8,000 kilometres behind the wheel of the Super Duty, it’s hard not to be impressed. It’s bigger, more capable, and more comfortable than anything we’ve owned before. It carries weight with ease, tows without complaint, and brings with it a level of modern technology our older Toyotas simply don’t have.

Sure, it’s a little thirsty. And yes, occasionally finding somewhere that sells AdBlue becomes part of the adventure. But those are small trade-offs when you step back and look at the bigger picture. Because what Ford has created here is something that sits in a very interesting space. It’s not trying to replace the Ranger. It’s not trying to be a luxury tourer. And it’s not pretending to be something it isn’t. It’s simply a heavy-duty tool designed for people who genuinely need one. And after living with it, building it, and taking it out into the real world, we can confidently say this:

The Ranger Super Duty might not be for everyone. But for the right person?

It might just be exactly what they’ve been waiting for.

Mt Disapointment, Victoria - Photos by Geolian

Let’s see what the future holds.

As more Ranger Super Duties begin appearing on Australian roads, being worked hard, tested properly and inevitably modified by owners across the country, it will be fascinating to see how the platform evolves. With new trim levels already being discussed and the aftermarket beginning to catch up with the eight-stud platform, this truck is only just getting started. If the early signs are anything to go by, the Super Duty could carve out a very interesting place in Australia’s touring and heavy-duty 4WD landscape. And like any good platform, the real story will be written not by Ford, but by the people who take them out there and see what they’re truly capable of. Would you buy one?