Portal Pros Prototype to Production | Ep.30

Overland Weekly Episode 30. Davey sits down with Matt and Scott from Portal Pros a year after their first appearance to cover everything they’ve learned building bolt-on portals in public: road miles, failures that made the product better, a wild Mickey’s Hot Tub rollover, production status, pricing, serviceability, upcoming vehicle support, and more. Plus, rapid-fire questions to wrap it up.

Highlights:

• New YouTube segment: Overland Weekly Trail Cuts (raw wheeling, no fluff)

• Portal Pros’ year in review: events, testing, and social growth

• Jeep build glow-up: 40s, shocks, steering, and why it finally drives “disgustingly” well

• Mickey’s Hot Tub rollover: what happened, what broke, how they wheeled out the same day

• 13,000+ road miles on portals: early issues and design fixes

• Gear evolution: 0.75" → 1" → 1.25" gears and why they’re sticking with it

• Output flange redesign after cumulative abuse (stronger geometry + alloy steel)

• Production status: pre-orders, deposits, shipping timeline

• Price/value: $15,000 for all four corners (axle shafts + hardware included)

• Serviceability: trail-friendly design, minimal hand tools, “dead hub” limp mode

• Modularity: move your portals from one platform to another with adapter sets

• Manufacturing & QC: vetted suppliers now, in-house machining later

• CTIS: sealing challenges, dual-separated air/oil path progress

• Future platforms under evaluation (Toyota TNGA/6th-gen 4Runner, older Jeeps/Toyotas, Super Duty D60)