Ford Kuga Overland Build
A look at turning a practical SUV into a capable overland vehicle.
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This Ford Kuga overland project shows that you do not need a traditional 4×4 to explore off-road.
With planning, research, and the right upgrades, this standard SUV has been transformed into a capable and practical overland vehicle.
Build spec – Ford Kuga overland setup
Suspension
- 40 mm lift kit
- Custom rear displacement cones (fabricated by a third-party workshop)
Wheels and tyres
Exterior
- Roof rack with full-size spare wheel and spotlights
- Misutonida 4×4 bullbar with integrated lighting
- Wind deflectors
- Bonnet deflector
From family SUV to overland build
I’ve owned this Ford Kuga for just over four years, though it has been in my family since it was bought new in 2010.
From the start, I wanted to make it more capable off-road and turn it into something different. The goal was clear: improve ground clearance, fit all-terrain tyres, and build a practical overland setup.
In summer 2025, I decided to go ahead with the project. It quickly became clear that building an overland Kuga would not be straightforward, as there are very few off-the-shelf parts available.
Suspension – the foundation of the build
I began with the suspension. After researching options, I found that Delta4x4 had previously lifted a Mk1 Kuga by 40mm, allowing for larger tyres such as 235/70R16.
To keep costs down, I sourced a 40mm lift kit from a supplier in Lithuania. The kit included polyurethane strut spacers for both front and rear, along with rear spring spacers.
While installation was straightforward, an issue appeared early on. After hitting a pothole, one of the rear springs dislocated. To solve this, I fabricated custom rear dislocation cones, similar to those used on Land Rovers.
Since no off-the-shelf solution exists for the Kuga, this modification was essential. After fitting them, the suspension proved reliable, even when the rear wheels lifted on rough terrain.
Wheels, Tyres, and Stance
Next, I upgraded the wheels and tyres, fitting 16-inch Tuff Torque Modular steel wheels with BFGoodrich KO2 all-terrain tyres.
This change significantly improved grip and durability, while the larger tyres added extra ground clearance.
I also fitted 25mm rear wheel spacers to widen the track, improving stability and giving the vehicle a more balanced stance.
Final thoughts
After extensive research, problem-solving, and hands-on work, the Kuga overland build is complete.
It remains practical for everyday use while also enabling off-road travel. More importantly, it demonstrates what can be achieved with a less conventional platform.
Now it’s time to use it as intended.
Follow the build
Follow the journey on Instagram: @overlander_kuga
photo credit @g3_cxo
