Thinking about a canopy and tray system? Look inside the build as we transform a 2026 Toyota Hilux

When it comes to building a touring-ready and work-capable 4WD, the gear you choose matters. Just as importantly, so does the way it's installed.

In the first episode of Inside the Build, we take a behind-the-scenes look at the transformation of a brand new 2026 Toyota Hilux (N90),showcasing what really goes into fitting a premium canopy and customising a 4WD build for a McCormacks 4WD customer. From workshop preparation and paint matching through to suspension upgrades and final handover, this build demonstrates why attention to detail makes all the difference.

Starting with the right foundation

This brand new Hilux arrived at McCormacks 4WD with a clear purpose: create a practical setup that could comfortably support our customer’s retirement and handle their exciting touring adventures around Australia.

The centrepiece of the build was a complete Boss Aluminium tray and canopy system. While tray and canopy installations can appear straightforward from the outside, the reality is that every vehicle presents unique challenges that need to be addressed properly if the finished product is going to perform reliably for years to come.

The first step of the build involved removing components and preparing the vehicle to ensure everything would fit correctly and function as intended.

Why proper fitment matters

One of the biggest misconceptions about tray and canopy systems is that they're simply bolted on and sent out the door. In reality, quality fitment requires careful inspection and problem solving throughout the installation process.

During this build, the team identified an issue where a mounting point interfered with the vehicle's fuel hose. While it may have technically worked in the short term, leaving it untouched could have eventually caused rubbing and potential damage.

This is exactly why experienced fitters take the time to check every mounting point, clearance and alignment during installation.

Rather than forcing components into place, the team modified and adjusted the setup to ensure:

These are the details customers rarely see, but they're often what separates a quality installation from one that causes headaches down the track.

Colour-matched for a factory finish

One of the standout features of this build was the full colour-matched canopy, perfectly integrated with the tray for a factory-style finish.

While the canopy arrives in black, McCormacks 4WD offers colour matching to help create a more integrated factory-style appearance.

The process is completed through our in-house paint department, where the doors are prepared, primed and finished using quality automotive paint systems.

The textured aluminium doors require additional preparation before paint can be applied. This involves:

The result is a tray and canopy combination that looks like it belongs on the vehicle rather than a collection of aftermarket accessories added as an afterthought.

Suspension to handle the added load

Adding a tray and canopy system brings significant benefits in terms of storage, organisation and functionality, but it also introduces additional weight.

To ensure the Hilux maintained proper ride height and handling characteristics, the build included an Ironman suspension upgrade, featuring:

This helps support the additional tray and canopy weight while improving vehicle stability and load-carrying performance.

For owners planning extensive touring setups, matching the suspension to the intended use of the vehicle is a critical part of achieving a balanced build.

Practical touring features

A major advantage of modern aluminium tray and canopy systems is their ability to be customised around the owner's specific needs.

This Hilux incorporated several practical touring-focused features, including Boss Aluminium's integrated water system complete with an electric water pump.

With the pump activated via an inbuilt switch system, water can be accessed quickly and conveniently when camping, travelling or working remotely.

The modular nature of the tray and canopy system also means the setup can continue evolving over time.

The tray provides the foundation of the build, delivering a durable and practical platform that integrates seamlessly with the canopy system. Together, the tray and canopy create a highly versatile setup suitable for both daily work duties and long-distance touring.

Owners can add accessories such as:

This flexibility allows the vehicle to grow with changing needs rather than requiring a complete redesign later.

Retaining modern vehicle technology

Today's vehicles come equipped with a range of factory safety and convenience features, and preserving these systems during modifications is essential.

Throughout this build, careful attention was paid to ensuring the Hilux retained its factory functionality, including:

The canopy's central locking system was connected to operate seamlessly with the vehicle's original key, providing convenience without compromising security while integrating with the overall tray and canopy package.

A complete build, all under one roof

One of the biggest benefits highlighted throughout this build was the ability to complete the entire project under one roof.

Rather than coordinating between multiple suppliers, installers and paint shops, every stage of the process was handled by the McCormacks 4WD team.

Everything was completed in-house.

This approach not only streamlines the build process but also helps ensure consistency, communication and accountability from start to finish.

The finished result

By the end of the build, this 2026 Toyota Hilux had been transformed into a practical and professional setup capable of handling it's upcoming touring adventures.

The combination of this build delivered a vehicle that looks great, functions exceptionally well and remains highly adaptable for future upgrades. The integrated setup provides secure storage, improved organisation and the flexibility to evolve with the owner's changing needs.

Most importantly, every component was installed with long-term reliability in mind.

Thinking about a canopy or tray system for your ute?

If you're researching canopies and trays, planning a touring setup, or looking for a more practical work vehicle, the right products are only part of the equation. Professional installation, proper integration and attention to detail play a major role in the finished result.

At McCormacks 4WD, we help customers build vehicles that are tailored to the way they actually use them—whether that's touring Australia, tackling demanding work sites, or doing a bit of both.

Want to discuss a tray and canopy setup for your vehicle?

And if you'd like to see this Hilux transformation from start to finish, you can watch the full episode of Inside the Build on the McCormacks 4WD YouTube channel.