Why I Upgraded My 4WD Suspension | Fulcrum Suspension BT-50 Build

Since owning my BT-50 for just over 12 months, I’ve actually upgraded the suspension twice — each time to better suit my touring setup and growing confidence off-road. As my build evolved and I started carrying more gear, it became clear that the inital suspension upgrade just wasn’t cutting it. I wanted to improve not only the vehicle’s clearance and stance but also the overall comfort and control, both on and off the road.

Both upgrades were carried out by Fulcrum Suspension — a brand I already knew and trusted. I’d seen their setups perform time and time again throughout the 4WD community, and their reputation for quality and reliability made them an easy choice for my BT-50 build.

Why I Needed an Upgrade:

When I first bought my BT-50, it was completely stock. Not long after, I set off on a four-week trip to North Queensland with that setup — and while it handled the adventure surprisingly well, it quickly showed me the limitations of factory suspension on a fully loaded touring rig.

After returning from that trip, I booked in my first suspension upgrade with Fulcrum Suspension to better suit my setup at the time, which included the tub, drawer system, tub rack, rooftop tent and camping gear. The difference was immediate — the BT felt more controlled, comfortable, and capable both on and off the road.

My long-term goal was always to fit a tray and canopy, although I didn’t expect that upgrade to happen quite so soon. If I’d known how quickly the build would evolve, I would have gone straight for a heavier spring setup from the start. To be honest, it wasn’t something I had researched deeply — I was only considering my setup as it was, not how it would grow over time.

As the months went on and I added more accessories, the extra weight started to take its toll. The rear of the BT began to sag noticeably, and once the canopy was installed, it became clear that my suspension needed another upgrade to keep up with the build.

Choosing Fulcrum Suspension:

One thing that really stood out to me after the first upgrade was how well the Fulcrum suspension performed, even through some of the toughest conditions I’ve driven so far.

That setup took me across the Gibb River Road — thousands of kilometres of corrugations, river crossings, and rugged tracks — and it handled it all incredibly well.

While the spring rate I was running at the time wasn’t necessarily ideal for that kind of load or terrain, it held together perfectly. The ride stayed stable, nothing failed, and I came away genuinely impressed with how well it performed under pressure. That trip cemented my confidence in Fulcrum and confirmed they were the right brand to continue working with as my build evolved.

So when it came time for the second upgrade — this time to suit the weight of the canopy, rooftop tent, bullbar and all the gear I now travel with full-time — I had no hesitation in going back to Fulcrum. Their team helped me select a setup that would handle the constant touring load, improve the stance of the BT, and give me the comfort and control I was looking for both on the highway and off the beaten track.

Installation Process:

After deciding on the second upgrade, I drove back to Brisbane to visit the Fulcrum team at Coopers Plains. From the moment I arrived, they were professional and thorough — assessing the BT, checking weights, and taking measurements to determine the right springs for my setup.

For this upgrade, we went with 400–500kg loaded springs, paired with some essential components to handle the touring load:

• Formula 4x4 shocks

• SuperPro upper control arms and bushes

Once the new suspension was installed, the team performed a full wheel alignment and remeasured the BT to ensure everything was set up correctly.

The result was a massive 70mm lift in the rear. While the BT technically retained the same 2-inch lift from the first upgrade, the added weight of the canopy and gear had caused the rear to sag over time — meaning I hadn’t been getting a true 2-inch lift until this second upgrade. The difference was immediately noticeable, with a more level stance and improved handling both on and off the road.

First Impressions on the Road:

The moment I hit the road with the new setup, the difference was undeniable. On the highway, the BT felt far more stable — smoother over bumps and corrugations, with less body roll through corners.

Taking it off-road was where the upgrade really shone. I’ve tackled muddy tracks, sand dunes, and rough backcountry trails since the upgrade, and the BT handled everything with far greater confidence.

The suspension soaked up bumps and corrugations effortlessly, keeping the rear planted and reducing the sag that used to make certain tracks tricky.

One of the most noticeable changes? Just how much more lifted the rear now sits. I joke that getting into my rooftop tent has become a legitimate workout — definitely harder to reach than before! But the added height and improved stance make it all worth it, giving me better clearance and a more commanding view of the tracks ahead.

Overall, the combination of Fulcrum springs, Formula 4x4 shocks, and SuperPro upper control arms has completely transformed the way the BT drives, both on and off-road. The upgrade isn’t just about lift — it’s about confidence, stability, and knowing my rig can handle whatever the road (or lack thereof) throws at it.

Why Suspension Matters for Touring Builds:

Upgrading your suspension isn’t just about getting a lift or making your 4WD look tougher — it’s a critical part of building a reliable touring rig. The right suspension affects safety, comfort, and performance, especially when you’re carrying heavy gear, towing, or tackling rough tracks.

A well-matched setup:

• Improves handling and stability on highways and winding roads, reducing driver fatigue.

• Maintains ride height and clearance, preventing sagging under heavy loads.

• Enhances off-road capability, helping your 4WD absorb bumps, corrugations, and uneven terrain without stressing other components.

• Protects your vehicle and gear from wear caused by excess movement or uneven weight distribution.

For touring builds like mine — with a canopy, drawers, fridge, recovery gear, and camping setup — suspension upgrades are more than an upgrade; they’re an essential investment in confidence and reliability. A stock setup may handle light touring, but as your build evolves, so should your suspension. Choosing a quality brand like Fulcrum Suspension ensures you have a system that can handle your rig now, and wherever your adventures take you.

Final Thoughts:

Upgrading the suspension on my BT-50 has been one of the most impactful changes to my touring rig. From the stock setup to the first Fulcrum upgrade, and now to the second, each step has improved comfort, stability, and off-road capability — letting me travel further and tackle tougher tracks with confidence.

Sarah Rose Foster