CTO Industries builds a touring-ready Chevrolet Silverado 2500

Full-size American 4×4 pick-up trucks are growing in Australia in more ways than just sales.

While they are bigger than the midsize utes that are more popular with users here, many full-size owners like to take their trucks to another level, and there is no shortage of products to help them reach their lofty goals. While some like to follow the SEMA Show style of over-the-top builds with massive suspension kits, huge billet wheels and lashings of chrome and candy paint, most Australians building a pick-up tend to go with a more subtle and practical style.

That’s what drew us to this Chevrolet Silverado 2500 from CTO Industries in Melbourne. Sure, it’s big and brash, but restraint was shown in the selection of components fitted, with CTO chasing high-quality parts from well-known brands for the truck ahead of bling and brashness.

The build is for Adam Cheers, who runs the Bob Jane T-Marts store in Moorabbin. Adam wanted a truck that had presence on the road but was nothing over the top, and he insisted on quality equipment throughout. The truck will mainly be used for touring, with plans to head to the Cape and the Kimberley in the coming years, so he wanted the right equipment to ensure it has what it takes to handle whatever the outback throws at it.

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Building a capable touring Silverado

The new truck went straight to CTO’s Kilsyth workshop from the GMSV dealer before it was even registered, where the specialist team set to work transforming the Chevy into what Adam envisioned.

“I wanted a touring truck that will be capable and comfortable,” Adam told us. “I’ve had a taste of travelling in the West, so I can’t wait to get the truck and head back over there to explore it some more.”

The suspension was the key component in the Silverado’s elevated status, and CTO specified a BDS five-inch kit with Fox remote-reservoir shocks. Rather than dropping the torsion-bar crossmember, CTO relocated the bars atop the lower control arms, preserving clearance, while the kit’s machined knuckles correct the steering geometry at the new ride height. The result is a great-riding, well-engineered solution for the build.

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The rear suspension retains its leaf springs, which are lifted in line with the front end but are aided by airbags and Fox shocks. The Boss Air airbags are controlled by a Logic iQ onboard air system with remote control, allowing the driver to set the ride height as required for towing and track conditions.

The BDS/Fox suspension setup affords the Chev an upgrade in capacity, and the truck is now rated to 5900kg GVM. While the GVM upgrades were being approved, so too were the 37-inch tyres that the suspension is designed to work with. CTO has its own team to carry out the engineering tests to ensure it all works as it should and is approved for road use.

With a wheel and tyre store at his beck and call, Adam had no problem selecting the 22×10-inch Fuel ‘Brawl’ rims and 37×13.5-inch Yokohama tyres. To keep the bigger tyres within the lines of the Silverado body, a set of flares from Husky Liners was fitted. Even these required some clearance to prevent any rubbing on the Yokies, and once that was sorted they were colour-matched to the vehicle.

The added ride height can also make life hard when accessing the vehicle cabin, so a set of AMP electric-deploying side steps was fitted to make things a bit easier. Speaking of the cabin, the spec GMSV offers in its 2500s is loaded with luxe, so there wasn’t much needed to ensure Adam will be touring in style. But the big cabin does have the perfect spot to mount a complete 12-volt setup – underneath the back seat.

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A 12-volt setup under the back seat

CTO makes a panel to contain all the components under the seat.

These include a Victron Energy 200Ah lithium battery mounted in a battery box, battery management system, 50A DC-DC charger and a 2000W compact inverter. Multiple USB, 12-volt, Anderson plug and other outlets allow the power to be used where needed. CTO custom 3D-printed the fascias for these, including the GPO outlet and a panel at the rear of the tray. The GPO had to be approved by a sparky for use in the vehicle, and this wasn’t a problem.

The setup is neat and secure, and its position under the seat means it is out of the way, while the power outlets are located inside and out where they can be easily accessed. A Victron solar panel is mounted atop the Higher Ground roof rack, along with a mount for Adam’s Starlink Mini setup and camp lights on either side.

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Touring gear up top

While many of the components on the Silverado are sourced from the USA, where there is an abundance of gear available, Higher Ground is an Australian company turning out quality stuff from its Melbourne factory, which is why CTO chooses to work with them.

The Higher Ground rack sits snugly atop the big Chev and even has allowances for the factory sunroof to let light into the 2500. On the underside of the Chev is a 211-litre fuel tank from Titan, while a 4500kg GEN-Y Torsion hitch is fitted at the back for towing when needed.

There are a few items still to be fitted to the Silverado before Adam takes it from the team at CTO, including a set of lights across the front of the roof rack and a bullbar for protection in the outback. Then it will be a matter of loading it up and hitting the road.

“I’ll probably put a canopy on it at some point,” says Adam, “but for now I want to enjoy it as it is.” That sounds like a great plan to us.

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Ready for the outback

After the careful selection of components, tasteful installation and quality workmanship from one-stop truck fit-out specialist CTO, Adam’s Silverado still makes a statement wherever it appears without being overtly brash or in-your-face. The modifications were well considered, functional and dependable, ensuring they will improve the performance of the truck for many outback miles to come.

Upgrades and modifications

• BDS five-inch suspension kit
• Fox remote-reservoir shocks
• Relocated torsion bars
• BDS machined steering knuckles
• Boss Air airbags
• Logic iQ onboard air system
• 5900kg GVM upgrade
• 22×10-inch Fuel ‘Brawl’ wheels
• 37×13.5-inch Yokohama tyres
• Husky Liners flares
• AMP electric-deploying side steps
• Victron Energy 200Ah lithium battery
• 50A DC-DC charger
• 2000W compact inverter
• CTO custom 3D-printed fascias
• Higher Ground roof rack
• Victron solar panel
• Starlink Mini mount
• Titan 211-litre fuel tank
• 4500kg GEN-Y Torsion hitch