Being a seasoned traveller, I get asked a lot about what equipment I use on my 80 Series, including what suspension I run. 

Well, a couple of years ago I changed to Outback Armour suspension components, and I can definitely say it’s some of the best gear I’ve used for the past 20 years, over which time I have clocked up tens of thousands of kilometres per year across multiple terrains Australia-wide.

Jumping onto the Outback Armour website, I chose the Adjustable Bypass Expedition HD kit for my needs, as my 4×4 is set up as an outback tourer, configured for remote missions with drawers, fridges, recovery gear and enough equipment to be off grid for weeks at a time. The HD Expedition kit ticked all the boxes and was easy to install over a couple of hours. Supplied with coils, shocks front and back, a steering damper, correction bushes and a shock service kit, there was nothing else I had to worry about.

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The Outback Armour story

It was in 2012 that Outback Armour started in a Queensland garage, where the founder first began making specialised suspension kits for armoured military vehicles that needed to be tough and durable to survive any terrain thrown at them. 

These vehicles were heavy with ballistic plating on and underneath, and also loaded with gear inside and out. Thinking outside the box, the founder also knew that modern-day 4x4s needed specialised suspension to cope with heavy loads such as steel bullbars, winches, canopies and internal drawer systems, as well as the weight of equipment loaded into the back of working utes. This was the beginning of Outback Armour, the name derived from the focus on armoured vehicles and the Australian outback.

Brad Bernard and Richard Catelan have led the charge from the start, and the company now ranks among the best 4×4 suspension component suppliers on the Australian market. Today it also has branches in North America and the Middle East, which allow real-life testing in the military field across various weather and tough terrain conditions.

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Suspension range, spring rates and GVM upgrades

In its range, customers can choose a variety of spring rates and shock variables to suit how much load a vehicle constantly carries. 

There’s a nitrogen gas-filled shock, which is the next step up from a factory setup and is designed for improved on- and off-road handling. Next is a digressive foam-filled shock, which has high-flow pistons for improved handling, especially over corrugations, and lastly Outback Armour offers its top-of-the-range fully adjustable 20-stage shock, where customers can fine-tune their 4×4 ride.

This is done with a simple knob dial on the shock. The spring range is similar, with three different load rates. The first is the Trail Spring, which is better than factory, next is the Expedition for vehicles with only a few heavy add-ons, and last is the Expedition HD for 4x4s that have many options added. Outback Armour also offers a GVM upgrade for many 4x4s so owners can stay legal while safely increasing load or towing capacity.

Outback Armour backs itself with a three-year unlimited-kilometre warranty, and it is Australian owned and operated with its gear tested in the harshest conditions around the world. All of its products are designed and developed in house in Brisbane and go through rigorous testing on vehicles before being certified to Australian standards.

This gives us as four-wheel drivers the assurance that Outback Armour products have been built for Australian conditions, successfully bridging the gap between heavy-duty military engineering and civilian off-road performance.

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Adjustable Bypass Expedition HD

I’ve never had adjustable shocks before and, to be honest, I really thought they were a bit of a gimmick, especially as the ones I ordered had a 20-setting range. 

Initially I had the front and rear set midway (10 clicks), but found them a bit soft on the highway and outback roads, as I have a roof-top tent, 270 awning and a shower tent up top. Clicking them up to 15 made a huge difference, with less sway on the roads, better control and reduced rebound bounce when soaking up bumps and corrugations. The 20-click adjustable bypass control on the shocks definitely works, and I’ve fine-tuned the ride to suit my comfort across all types of terrain. It’s possible to dial the shocks right down to give the vehicle a really soft feel on harsh terrain such as when rock crawling.

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Over two years with the Outback Armour suspension fitted to my 80 Series LandCruiser, I’ve travelled extensively through Arnhem Land, across the rocky terrain of the Flinders, through deserts where roads are littered with corrugations, right down to Tassie, plus tackling hard tracks around the Coffs Coast. The only thing to date is that the suspension has suffered from sand and rock rash, but this is all part of travelling on outback roads.

It’s recommended that once a year owners check the shocks as part of a maintenance program and, if the shock dials feel notchy or clammed up, complete a service procedure. Online, Outback Armour runs through servicing and other suspension tips for its range of products. The adjustable bypass shocks that I chose have a massive 65mm body with a 40mm high-flow piston and heavy-duty internal valving, and they come with a toughened cover protecting the 18mm hard-chromed shaft to prevent stone or dirt damage.

I’ve tried multiple suspension brands over my extensive 4×4 lifetime, from ones that claim to be big bore to top-of-the-range brands, but I’m putting Outback Armour up there as the best.

Pricing and more information

I paid just over $2200 for my setup. There are cheaper options through the range, but you’ll need to assess what your needs are. All prices, suspension specifications, service requirements, dealer locations and other links are on the Outback Armour website.

Outback Armour also sells a range of 4×4 recovery kits, components and accessories that comply with Australian standards, and some to military specs. Prices and certification for all its gear are also available online.

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