GMT 800 Tahoe Turned into a Mad Max Rat Rod Off-road Build
- Class: 4WD Body-On-Freame SUV
- Style: Off-road Rat Rod
- Platform off-road capability: 74.5/100 Points
- Build difficulty: Advanced
- Budget: $
When you think of a capable dune rider, you probably picture a $30,000 side-by-side or a highly modified Jeep. But Chad Nicholls and his son Mason from Toledo, Ohio, have proved you can build an absolute head-turner adrenaline machine for under $1,500. They have turned a wrecked GMT800 Chevy Tahoe into the post-apocalyptic, Mad Max-style off-road rat rod with an open top that looks incredibly awesome! Read on to find out more about the modifications they’ve done to this Tahoe and get an ideal blueprint for your own Rat rod Build!
Build Specifications Table
| Spec Category | Component / Modification Details |
|---|---|
| Spec Category | Component / Modification Details |
| Donor Vehicle | 2000 Chevy Tahoe / Suburban (GMT800 Platform) |
| Engine | 5.3L V8 (Complete rebuild, Engle Sloppy Stage 2 Cam, PAC 1218 Springs) |
| Transmission & T-Case | 4L65E Automatic / Manual Transfer Case from a ’96 Blazer |
| Tuning Software | TunerPro via open-source PCM Hammer (Custom OS on factory PCM) |
| Front Suspension | Factory Torsion Adjusted with Bilstein 5100 Series Shocks |
| Rear Suspension | Custom Fabricated Lift with Bilstein 5160 Series Remote Reservoir Shocks |
| Tires & Wheels | 15″ American Racing Rims; 33×13.5 Super Swamper TSL Boggers (Rear) |
| Body Modifications | 47 Chevy 4400 Dump Truck Hood, International Harvester Combine Grille |
Interview with the builder
“a bright example of creativity, daring ideas, and unique style, a truck that looks like it just rolled out of the Mad Max post-apocalypse movie”
Why did you choose the off-road build way?
– I have vacationed at Silver Lake Sand Dunes, in Mears, Michigan starting when I was 11. We were surrounded by amazing dune toys of all kinds, VW powered buggies, jeeps, trucks. I loved hearing the roar of the engines, folks working on fixing their rigs, it was amazing to me.
Over the years we made friends that would take me along, it was like going to another planet surrounded by sand, cool rigs, and cool people. I wanted in.
Why did you pick a Chevy Tahoe GMT 800
– The short version of the story is, we bought the Tahoe for $400 that was in a rollover accident. We wanted the engine and transmission for my son’s 46 Ford rat rod. I cut the roof off so I could open the doors up and drive it around on our property, after removing the hood, I covered the engine with an old grain truck hood, and thought hey that looks pretty cool.
When Covid hit, we got the idea to see if we could build the Tahoe for the dunes using only what we had on hand. With our four children being home schooled we thought it would be a good opportunity to demonstrate that junk can be repurposed. Having it seat 7 people we could all ride together safely got the wife’s approval.
What inspired you to build a Mad-max off-road rat rod?
– It was Covid after-all and the vehicles from mad-max has always been my all-time favorite. So The theme was us post apocalypses, not recreating a mad-max vehicle but more of a tribute.
Most people who know me know we are into old cars so with scrap value had been very low at the time, We had a decent pile of old scrap metal that we acquired. So most everything on Max was taken from the scrap heap.
What challenges did you face while putting it together?
– Just making everything come together so you don’t really know what is old, and what was new.
What was the end budget of this build?
– I love the fact that we have spent less than $1,500 in the whole project. It’s covered in rust, on purpose, and when we sit next to $30K purpose-built sand cars, everyone is drawn to Max.
Just driving around town everyone who sees it immediately smiles, gives a thumbs up, or takes pictures of it. We go off-roading in the sand dunes or trail riding every weekend.
Rat Rod Parts & Off Road Upgrades
Engine
- Complete Rebuild
- Engle (sloppy) Stage 2 Camshaft
- Pac 1218 Springs
- Manual transfer case from a 96 Chevy Blazer
- 4l65E Transmission
- Efi uses the factory PCM modded to a custom OS Using Open Source PCM Hammer
- Tuned with TunerPro (Free Tuning Software)
Lift height and suspension
- Fabricated Rear Lift
- Factory Torsion Adjusted Front
- Rear Bilstein 25-187625 5160 Series Shocks
- Front Bilstein (24-186643) 5100 Series Shock Absorber
Wheels
- Used 15 Inch Aluminum American Racing Rims
- 33×13.5 Super Swamper TSL Boggers Rear
- 33×12.5 Goodyear Wrangler
Exterior Modifications to get that Mad Max Aesthetics
– I Removed Roof, Fabricated Front End using various scrap metal Hood from a 47 Chevy 4400 Dump Truck it was widened 12″ and the functional hood vent is the gas tank of a 1941 Model A Farmall Tractor split in half, grill was made from an International Harvester combine thrasher wheel, and rebar, the fender side panels are aluminum from a carrier refrigeration unit, and mesh fenders we salvaged from the insides office cubicle walls. The 50″ light bar lights up the trails like high noon. The headlights are cans from old KC lights, that are held by welded skeleton bolt hands. The halo lights led headlights are made for motorcycles.
Interior mods for Open Top Driving
– Removed all carpet and non essential accessories, seats 7 comfortably. Added a control switch panel for lighting, 4×4, fans and AFR Gauges.
Roll Cage and Rat Style Bits
– The Roll Cage we bent all of our own 1-3/4″ tubing with our fully hydraulic homemade tubing bender, we used an Affordable Bender Die Set. All the paint was then ground off and force rusted using vinegar, hydrogen peroxide, and Epsom salt.
We cast the terminator skull emblem in our homemade aluminum foundry. First we modeled and 3D printed the skull in plastic, then casted it in plaster, then melted out the plastic and filled it with aluminum recycled from window frames.
A word of inspiration for all custom builders
– Hey if you want to get off-road and you don’t have thousands sitting around for a side by side or a jeep. You don’t need a fancy paint job (or any paint) for people to respect your rig. Even if they hate your ride, forget them, it’s yours, have fun, in the end if it breaks it’s paid for…Get on marketplace buy a Junker and get to work! Don’t feel you have to be like everyone else, make it yours. You don’t need to have the best to have fun, just get started”
Author’s Opinion
As a longtime off-roading enthusiast and DIY mechanic, I can say that GMT800 platform (1999–2006 Chevrolet Tahoe, Suburban, Silverado, and GMC Yukon equivalents) is one of the best you can start with. The factory hydroformed frame offers immense structural rigidity, and the 5.3L generation-three LS-based V8 engine responds incredibly well to simple modifications like the “Sloppy Stage 2” camshaft installed in this rig.
Replacing the electronic transfer case with a manual unit from an older Chevy vehicle provides bulletproof mechanical engagement on trail runs.
The off-road tech is pretty strong too thanks to the classic low range transfer case and the rear locker available on Z71 models. One of the biggest advantages is the wheel size, which equals to 30″ in the factory specification, but the wheel arches can accept much more than that (especially if you don’t mind cutting them).
Thanks to all of above it gained an impressive 74.5 points out of 100 possible based on our stock vehicle off-road capability evaluation system. See how it compares to other platforms using our side-by-side comparison tool:
Chevrolet Tahoe Z71 GMT800 (2000-2006)
Score:
Toyota 4Runner 2nd Gen (1990-1995)
Score:
The creative fabrication work on this Chevy Tahoe rat rod is really impressive. While it’s pretty far from a real desert racing prerunner in terms of durability and the fab work, it does work great as a show and fun build.
While the GMT800 hydroformed frame is exceptionally rigid, chopping the roof off reduces the body structure’s contribution to overall rigidity and torsional stiffness.
This build is perfect as a sand dune cruiser and showstopper, but it isn’t designed to take high-speed desert whoops or hard rollovers without a fully tied-in, chassis-mounted roll cage. Putting together a rig that complies with modern safety standards, let alone motorsports standards – does take time and investment. Perhaps this is where the invisible difference lies between a $1,500 and $30,000 desert off-road vehicle.
Related Parts & Mods
– Inspired by this Mad Max-style Tahoe rat rod and looking to build your own GMT800 dune cruiser? Our team has put together a list of products and accessories available online that may help you achieve similar results:
Off-Road Tires
- Interco Super Swamper TSL Bogger – The same aggressive mud/sand tire running on the rear of this build *Verify the size that fits your wheels and lift
Suspension & Shocks
- Bilstein Shock Absorbers – Bolt-on ride upgrade for GMT800 Tahoe / Suburban / Avalanche platforms, like the 5100/5160 setup on this rig
LED Lighting
- Nilight 50″ Curved LED Light Bar – 288W spot/flood combo to light up the trails like high noon, just like the 50″ bar on this build
Winch
- Smittybilt XRC GEN2 9,500 lb Winch – Waterproof recovery winch for getting unstuck out in the dunes and on the trail
*Always verify product compatibility for your specific vehicle with a seller before purchase. Specs and fitment may vary by model, year, and trim level. We are not responsible for fitment or other issues that may arise from using the products listed above.
