Expedition Vehicle Automation
Optimizing Usability:
Linear Actuators in Retractable Side Steps
IP65
Exposed Outdoor Environments
Compact
Fits Tight Chassis Clearances
Fast
Quick-Deploying Steps
Creator
The Overland Series
Industry
Automotive
Location
Canada
About The Overland Series
The Overland Series documents the complete ground-up engineering, restoration, and field testing of Pegasus, a 1959 Land Rover Series II built for long-distance expedition travel. They are currently travelling the Pan-American Route, from Canada to Argentina. Operating in remote locations means every system on the vehicle must balance modern mechanical convenience with rugged, field-serviceable reliability.
Introduction
The Overland Series partnered with Progressive Automations to bring linear motion solutions into custom retractable side steps. Because the build was intended for rugged off-road conditions, the selected actuator provided smooth operation while supporting durability and reliability in a challenging environment.
Custom Retractable Steps
Custom Outdoor Automation in Extreme Environments
Building a capable expedition vehicle for The Overland Series requires maximizing ground clearance and capability with long-distance travel comfort and usability. The upgraded seats and increased ride height of Pegasus introduced a daily ergonomic challenge for cabin access. Fixed running boards or side steps were out of the question, as they would severely compromise off-road break-over angles and catch on trail obstacles.
To solve this, the step system needed to be fully retractable; deploying automatically when the doors opened and folding beneath the body line while in motion. Actuators needed to fit within tight chassis clearances without exposing delicate components to rocks or debris. The mechanical drive system had to endure mud, road salt, water crossings, and freezing temperatures, all while deploying and retracting fast enough to be useful.
Primary Requirements
Compact Integration
Environmental Resistance
Fast Speeds
Supplier Transparency
12V Actuation
Reliable Motion Integration
How Progressive Automations Supported the Retractable Side Steps System
To actuate the custom-fabricated step mechanisms, linear actuators from Progressive Automations were selected to meet the exact force requirements, speed, and stroke lengths dictated by the step geometry. The PA-01-4-56-N-12VDC was chosen as it offered the suitable force, speed, and stroke capabilities to handle the side step deployment, all in an IP65 water-resistant compact design. Operating at 12VDC, it allowed for system compatibility with Dan’s control strategy of simple, robust, and repairable components.
Rather than over-complicating the system with complex microcontrollers, the actuation logic was engineered using a high-reliability, polarity-reversing 12VDC relay circuit. Integrated door-jamb switches trigger paired SPDT automotive relays to deploy the steps when a door opens and retract them when closed. For safety, the system includes cab-mounted override switches for locking the steps in the stowed position during deep off-road crawling, alongside dedicated inline fusing and heavy-gauge wiring.
Highlights
EXPEDITION-READY
Handles harsh trail vibration, moisture, and extreme temperatures
OPTIMIZED CLEARANCE
Folding design preserves aesthetics & off-road capabilities
FIELD REPAIRABLE
Utilizes easy-to-service 12V automotive relay logic
PRECISE FITMENT
Seamless integration with custom-fabricated brackets
Improved Convenience and Usability
The Lasting Impact of Actuator Automation on the Final Build
By integrating Progressive Automations actuator systems, Dan from The Overland Series was able to create modern automated features that improved both the convenience and usability of Pegasus retractable side steps. The actuator systems also helped simplify the integration process by providing a compact solution with precise fitment and 12V system compatibility.
This contributed to the overall value and uniqueness of the final build, blending modern capabilities while preserving the classic aesthetics by folding under the body. For Dan, the project reinforced the value of selecting an actuator supplier that provides more than just hardware. Detailed engineering documentation, supportive technical assistance, and confidence in long-term reliability all played important roles in the success of his project.
experience
Detailed Technical Specifications & Clear Communications
Dan’s Journey with Progressive Automations
Dan first discovered Progressive Automations while searching online for reliable actuator systems for his custom expedition vehicle automation project. When comparing online market options, they often lacked detailed technical specs, force ratings, and wiring documentation. For an off-grid vehicle traveling hundreds of kilometers from the nearest shop, reliable technical data and high-quality components were non-negotiable. As the project’s primary decision-maker, he compared several suppliers based on technical specifications, durability, support, and overall confidence before choosing Progressive Automations.
His experience with our website was positive, noting that our detailed CAD files and complete electrical specifications allowed precise geometry planning on the bench before any metal was cut or welded. Our support team was also responsive and helpful during the planning stage, offering clear communication that supported the project’s requirements and smooth implementation. The combination of product information, actuator selection, and technical support helped Dan complete a custom automation project designed around both function and presentation.
Features
Compact Integration
Environmental Resistance
Fast Speeds
Supplier Transparency
12V Actuation
Elevate Custom Vehicle Automations with Progressive Automations
Custom expedition vehicle automation projects often require more than standard hardware. They need linear actuator solutions with precise fitment, high capabilities in compact designs, and the ability to operate with quick movements within the intended environment. Progressive Automations helps builders, contractors, and fabricators integrate electric linear actuators into custom automotive and off-road automation projects through technical support, a wide range of products, and dependable motion control solutions. If you have questions about actuator sizing, installation planning, or product selection, our team is here to help you find the right solution for your application.
