The Rugged Radios Baja RZR

Rugged Radios Baja RZR

Rugged Radios Baja RZR

Rugged Radios owner, Greg Cottrell, is no stranger to innovation. Whether it’s staying ahead of the curve with constant product development, or creating industry-first equipment for race teams, Greg is always a step ahead. With the popularity of UTV’s growing fast, Greg came up with an idea that was even faster. An idea that he wanted to be debuted at the largest off-road expo of the year, the Sand Sport Super Show. When you take into account that the entire project, from inception to completion took only 4 months, you can start to understand Greg, and Rugged’s, “always on-the-gas” mentality.

Greg’s fondness for VW Bugs started as a kid, with his dad racing the Baja 1000 in a Class 11. This inspired him to do something that had never been done before; merge the style, body, and feel of a VW Bug, with the versatility, power, and durability of a 2015 RZR XP1000. Long hours were spent in the NV Fab garage, where shop owner Nick Valentine worked to merge these two distinct ideas into what’s famously known as “The Baja RZR”.

Rugged Radios Baja RZR Chasis







  • Frame (brand/type): 2015 Polaris RZR
  • Fiberglass front clip with molded aluminum door panels
  • Mods done by: NV Fab, Oceano CA
  • Paint: Crocketts Premier Auto Body, Arroyo Grande, CA
  • Wrap: Linson Signs, San Luis Obispo, CA
  • Wheelbase: 93 Inches
  • Track Width: 76 Inches
  • Sand Tires and Wheels: Fullerton Sand Sports custom white aluminum wheels with Desert Trak Custom grooved Sport Tires
  • Offroad Tires and Wheels: Custom made American Racing Wheels with BFG All Terrain T/A’s


  • Make: Polaris 4-Stroke DOHC Twin Cylinder
  • Displacement: 999cc
  • Year: 2015
  • Induction Type: Boondocker Turbo
  • Headers/mufflers: Gibson Exhaust
  • Engine build-up/modifications done by: Boondocker
  • City/State: Idaho Falls, Idaho
  • Dyno/estimated horsepower: 175hp
  • Axles: RCV Performance


  • KC HiLiTES
  • Rugged Radios RRP6100 Race Intercom System with 50 Watt Radio.
  • Rockford Fosgate Speakers with Rugged Radios WM1 Bluetooth
  • Wiring: Positive Ride Travis and Kyler Jecker
  • Fresh air system: Rugged Radios Dual MAC1 Carbon Fiber Air Pumper System


  • Custom Stitched PRP Racing Mexican Blanket Seats
  • Dash: Modified Factory VW fiberglass Dash
  • 4 Point PRP 2.5 Harnesses
  • Baja style chrome steering wheel
  • 8-Ball Shifter Knob


  • Front Suspension: HCR Long Travel Suspension
  • Rear Suspension: HCR Long Travel Suspension
  • Front shocks(brand/type): 14” KING 2.5 Internal Bypass Shocks with Remote Reservoirs and finned reservoirs
  • Front springs: KING
  • Rear shocks (brand/type): 14” KING 2.5 Internal Bypass Shocks with Remote Reservoirs and finned reservoirs
  • Rear springs (brand/type): KING


4 comments on “The Rugged Radios Baja RZR
  1. António Cuco says:


    I Have a 2015 RZR NO -turbo. Do YOU Have The Baja kit available for sale? What Is The price?

    • Rugged says:

      Antonio, we offer a LOT of kit options. The only thing that makes them specific to a vehicle is the mount you choose. All other components will work in just about anything. In this case, you would want a mount for the RZR (available here). You can then make a kit selection with radios here or without radios here.

      • Gradie says:

        We want the VW body parts for our RZR. Where can I buy the body kit?

        • Rugged says:

          Unfortunately, that was a completely custom build and the body work is a total “one off” design and not mass produced. We quickly learned these would be a huge success if they were readily available. Thanks for taking a look and interest in the Baja RZR. It’s been one of the most popular builds we’ve done to date!

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