Darling, you can never be too skinny or have too much RAM.
There are two schools of off road vehicle weight, one is to weight as little as possible and dance over the top of obstacles, the other is to armor up, strengthen everything and force you way through. The Suzuki Sidekick school and the duce and a half school.
Body armor and heavy duty parts add weight which means you need them more. The less you weigh, the less you need heavy weight reinforcement.
What base vehicle you have largely determines which school you will be in. What you do with your vehicle will determine how much weight you can add or remove from base stock.
Personally I'm in the school which believes that you pack as lightly as appropriate for the trip mission and add the least amount of weight as possible to the vehicle itself as needed to get the loaded vehicle there and back with a high degree of reliability.
Say what?
I suggest using the most appropriate gear for your trip. For instance, back pack cooking gear is optimized for light weight and compactness, not for doing a good job of cooking your meals. Nestable thick wall aluminum pots & pans take up more space and weight but are much better at allowing you to cook a tasty meal. Anyone can put up with most anything for a weekend but if you are going to be out for a couple weeks you want to be as comfortable as possible. So for a weekender or long weekend, a back pack cook set is OK and saves a couple pounds. But for a week or longer the extra weight of think wall aluminum cookware is offset by your ability to more accurately control your cooking. Aluminum cookware requires less energy to cook a meal than steel or iron and saves propane weight as a side effect. There are a lot of choices like that which can be influenced by the length of trip you are taking and the environment you will be traveling through.
Try to build your vehicle as light weight as possible. Don't add the weight of body armor for just in case as the extra weight will make just in case more probable. Remove weight if you can. If you don't need rear seats, take them out. I started with a stock vehicle and discovered that I didn't need body armor for the places I drive and the kinds of driving I do. I added a rear diff protector because I can not see where I'm placing my rear diff whilst backing up. And that's it for my just in case armor. I rely upon driving technique and a strong sense of self preservation to get my vehicle through undamaged. When I break something once I assume it was wear or chance. When I break it a second time I feel that is because the part is too weak and needs upgrading.
Most suspension or drive train mods don't significantly change the vehicle weight but they do tend to add more which in tern may require additional upgrading to handle the extra weight.
My suggestion:
- pack appropriately for the trip, keeping the weight down without sacrificing function
- Minimize excess vehicle weight by removing what you are not using and not adding things that you have not proven that you need. Just in case mods add weight which in turn makes just in case more likely to happen.
weight is the enemy, driving technique is your friend that can negate the need for extra weight