Off-the-shelf gear doesn’t cut it when you’re deep in the backcountry. Here’s why custom steel and aluminum fabrication is the smarter choice for serious overlanders.
Posted by Hot Metal Fab | Loomis, CA
When it comes to outfitting your rig, choosing between steel and aluminum isn't just about weight — it’s about purpose, performance, and what kind of abuse your gear is going to take.
At Hot Metal Fab, we work with both steel and aluminum every day. Here’s a quick breakdown to help you decide which metal belongs where on your overland setup.
When to Use Steel
Steel is the go-to for strength, durability, and impact resistance. It’s heavier, but when you’re sliding over rocks or dealing with real-world trail punishment, nothing beats it.
Best for:
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Rock sliders (especially weld-on or frame-mounted)
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Bumpers
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Recovery points and brackets
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Heavy-duty bed stiffeners
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Armor and skids
Why steel?
Because when things go sideways, steel shrugs it off. If you're building for serious trail use, weight isn't the priority — strength is.
When to Use Aluminum
Aluminum is the lightweight champ. It resists rust, doesn’t weigh down your rig, and still brings solid strength — especially when you know how to brace and weld it right (which we do).
Best for:
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Modular bed racks
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Roof platforms
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Storage panels and interior systems
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Light-duty racks
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Cosmetic parts and trim
Why aluminum?
It keeps your center of gravity low and won’t corrode. For long-distance trips or daily-driver rigs, aluminum helps keep things nimble without sacrificing functionality.
Our Take: Build Smart. Use Both.
There’s no need to pick one side — the best builds use both metals, depending on where and how they’re used. That’s the beauty of working with a shop like Hot Metal Fab — we design everything in-house, and we build with the right material for the job, not just what’s easy to work with.
Need help planning your setup?
Give us a shout. Whether it’s a fully-welded steel slider or a modular aluminum rack, we’ll help you get it dialed.