Humvee DIY Upgrade – How to Convert 2-Man HMMWV to 4-man HMMWV

Humvee DIY Upgrade – How to Convert 2-Man HMMWV to 4-man HMMWV What we will cover Why Convert 2-Man HMMWV to 4-man HMMWV? What parts are convert a HMMWV from 2 […]

Humvee DIY Upgrade – How to Convert 2-Man HMMWV to 4-man HMMWV

What we will cover

  • Why Convert 2-Man HMMWV to 4-man HMMWV?
  • What parts are convert a HMMWV from 2 man to 4 man?
  • Steps to remove 2-man Humvee top and hardware
  • Steps to install 4-man Humvee top and hardware

Why convert a HMMWV from 2 man to 4 man?

  • More passenger capacity
  • More room for gear inside the cab
  • Aesthetic reasons

The Project Humvee Battlewagon ended it’s military career in 2-man Troop carrier HMMWV configuration.

Project HMMWV Battlewagon: Surplus HMMWV from the US Army - right side

We immediately removed the troop cover, troop cover bows and radio antenna arch prior to loading on the trailer for transport back to Gear Report HQ… and never put them back on. For 5 months we drove the Battlewagon in the 2 man pick-up truck configurations like this:

Gear-Report.com Project HMMWV Battlewagon - with stickers

It was great in the winter having a smaller volume of area to heat with the notoriously under-powered HMMWV heater. Once we added some Reflectix to the roof, it stayed warm enough inside. However, there really isn’t much room inside for any sort of gear. Even a simple range trip often meant tossing most of our guns and gear in the bed where it was exposed to the elements.

Project Humvee Battlewagon Interior - HMMWV interior

More importantly, there are more than two people on the Gear Report team. It just made sense to convert the Battlewagon to the 4 man configuration.

Here is how the Battlewagon looked after the basic conversion (still need to install the rear cargo cover)

Parts required for conversion of 2-man HMMWV to 4-man HMMWV:

You can order a complete 4 man HMMWV soft top kit from Breton, an OEM manufacturer. However, they are rather spendy. If you are on a tight budget, then probably your best bet for finding the HMMWV parts is on eBay (link).

 Where to get Humvee parts:

  • Probably my “go to” for real military parts is HMMWV parts on ebay
  • You can get HMMWV books on Amazon
  • Actually, you can get a LOT of upgrade parts on Amazon. We have made it easy by adding a HMMWV section the Gear Report Amazon store and add parts to it as we find them.
  • Southern Metals Recycling… if you happen to be close to Wilmington, NC. They scrap HMMWVs for the government and can sell some parts.

Steps to convert a 2 Man Humvee to a 4 man Humvee

1) Remove old top

2) Remove old hardware

*Hint: You don’t need to remove these… Yeah… I took them all off before realizing I should have left them on.

 

Parts you WILL need to remove:

  • Troop seats and/or cargo area side rails

  • *Optional: Remove the 2 man cargo divider, if installed

… or don’t. It is up to you. I took my 2 man divider out to give better access to the center area between the seats and will add a 4 man cargo divider just behind the back seats, between the wheel wells.

  • *Optional: Removing the doors may make it easier to move around the HMMWV, but is not required. (Removal of trailer is not required either)

  • Soft top bow (remove from the 2 man side rails if reusing on the 4-man top)

  • 2-man soft top side rails


3) Clean

Yeah. I know… you don’t like to clean.
I don’t either. However, there is likely a vast accumulation of dust, dirt, grime, sand, NBC, etc. hiding in the places normally covered by the top. Go ahead and spray them down while the top is off and it is easy.
Pressure wash hmmwv

4) Install HMMWV 4 man hardware

  • Install C Pillar (2 bolts on each side)
    Install HMMWV c-pillar  

  • Install 4-man soft top side rails (maybe yours will use the correct bolts. Mine didn’t)

  • Check C pillar turnbuckles and replace any damaged ones

    … and yes, I agree this should have been done BEFORE installing the c-pillar. Since I didn’t notice it before, I waited until the side rails were in place to hold the C Pillar steady while I drilled out the rivets on the broken turnbuckle, then pop riveted a new one in it’s place.

  • Install two soft top bows on the soft top side rails

  •  Install the HMMWV 4-man soft top and rear curtain

    Slide the enclosed rope at the front of the top into the channel on the top, front edge of the windshield. Do this with the top upside down.

    Once the top is in the channel you can pull it over the windshield…

    … over the B pillar, then over the C pillar

    … and attach the top to all of the turnbuckles along each side and along the back.

    Finally, wrap the velcro loops around the bows and B pillar

  • Install rear seat belts

  • Install rear door hinges and strikers

Two hinges per door = four hinges held in place with two screws each = eight screws…
unless you wring the head off of one of the screws like I did. 🙁

Striker installation

Install retaining straps on B Pillar

  • Install rear seats

    I installed the stock rear seats, briefly before swapping the seat  base covers onto a pair of HMMWV high back seats
     

  • Install doors

  • *Optional: Install 4-man cargo divider

 Where to get Humvee parts:

  • Probably my “go to” for real military parts is HMMWV parts on ebay
  • You can get HMMWV books on Amazon
  • Actually, you can get a LOT of upgrade parts on Amazon. We have made it easy by adding a HMMWV section the Gear Report Amazon store and add parts to it as we find them.
  • Southern Metals Recycling… if you happen to be close to Wilmington, NC. They scrap HMMWVs for the government and can sell some parts.

HMMWV stuff

More HMMWV articles can be found under the Humvee category menu above or by clicking HERE. You might also like the HMMWV section of our Amazon store where we have listed lots of replacement and upgrade parts for Humvees. We have also found a lot of HMMWV parts on eBay (link).

Suggestions?

Please leave a comment if you have suggestions on other HMMWV upgrades should consider, or you have done upgrades that we can share on Gear Report.

The Project Humvee Battlewagon

Gear Report acquired a real HMMWV (High Mobility Multi Wheeled Vehicle) from the US Army for use as our official field and shooting range vehicle. We have already posted about some of our upgrade projects (Project Humvee Battlewagon article links) and have a lot of really cool projects on the way. Consider subscribing so you don’t miss any of the cool reviews as we post them.
Here is our Project Intro (link) and our list of HMMWV upgrade projects.

 Gear Report YouTube channel

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About Jeff

Jeff is the Editor in Chief of Gear Report and a National Shooting Sports Foundation Media member. He reports on the outdoor industry, reviews gear for camping, hiking, shooting, hunting, paddling, backpacking and other active pursuits.

A USAF veteran, Jeff earned a MBA in Marketing and Health Services. He specializes in consultative selling and internet marketing. As the VP of BD & Marketing, Jeff provides sales and marketing leadership to MGECOM, Inc. and helps http://MGECOM.com acquire new clients in need of solutions for online merchants in need of Affiliate Marketing program management.

Jeff founded and manages Cress Sales & Marketing LLC, offering online sales and marketing consulting and services to online merchants and service providers.