roosterk0031: Thanks for the mention of the Grand Vitara and the Sorento. Both are possibilities if I can manage the seating - they have a "divide the cabin in two" style center console design, expressly what I do not want. The earlier Vitara (2001-2005, possibility 1998+, but crash results are missing 98-00) versions had a console style that looks removable, but I'll need to research more. Apparently some XL-7 parts/previous generation parts can be swapped in to allow fitment of lower gears, locking diffs, and aftermarket low-range gearing, etc. 2006+ looks more integrated interior-wise, and there's no aftermarket driveline bits that I can find. The Sorento I need to dig into more still.
aardvarcus:
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I think you are on the right track with the GMT400 Blazer. I've pulled out that era bench seat, didn't even take an hour to remove or reinstall. Ideal would be one with the 6.5L diesel and NV4500 Transmission. If you didn't want to deal with the nuances of that era diesel, a 350 with NV4500 would be a decent runner up. The NV4500 is an easy swap in an early version with the 4L60 before they switched to the 4L60E, did that in my old GMT400 K2500, don't have to even touch the electronics. Combine that with 3.08 or 3.42 differential ratio and you would easily be in the 20+ MPG range. A 4 door Blazer/Tahoe/Yukon/Denali/Escalade would only be slightly longer and heaver, and much easier to find.
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No diesels, unless I can get 20-30% better fuel economy than gas while driving 10 miles one way from a cold start without murdering it. My usage pattern means 10 mile drives a minimum of 9 hours apart (120VAC 15A available both ends), with a monthly ~35 mile one way, 1.5 hr stop with no power outlet access, ~35 mile return trip.
Which means a related question: How do you keep cold starts/short trips from killing a diesel? Are IDI better than DI for such duty?
The 4-doors are quite plentiful around here. If I could score a Hybrid that would be awesome, but GMT800 and a more complicated seat swap due to very much more integrated console due to a high option count on those rigs. Plus a min buy of $10k apparently, and still only ~20mpg. Great base for "more battery" mods, though.
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The other option would be a custom seat swap into your vehicle of choice. Stick to a model before they started to put airbag sensors in the seats or you are asking for trouble. I am really impressed with my wifes 2000 4Runner Limited, which is a good size (not to big or small) in my mind. Hers has the Multimode Transfer case (2WD, AWD, 4WD, N, 4WD-L) and rear differential locker, so just about as versatile as you could ask for offroad.
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I'm hoping to keep the seat swap "in the family" to make it hopefully easier. The Toyotas, while great trucks, are either expensive or have rotted out frames or both up here, unfortunately. I did have an FJ40 before, hard to beat.
Hersbird:
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If a full size Chevy Blazer is small what is a big SUV?
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It and the full size Ford Bronco are the "smallest of the large". They are not small, but are not a Suburban or Crew Cab Longbed. They are the smallest with room for a real bench seat with useable-by-an-adult front center passenger position.
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I'd look for XJ 4.0 liter Cherokee and swap in a bench seat from a Comanche pickup.
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The Cherokee has a good safety rating and excellent aftermarket stuff, but I need to figure out the seating - a bench is no good if the center only fits a 10yo, and the buckets are IIRC too far apart for what I want. Just scooting the passenger seat over won't work unless it is a non-airbag vehicle with a uniform dash shape. The early XJ's and Ford Explorers had no passenger airbag but still got 4* passenger crash ratings, so may be workable.
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This is why I am asking for info on small 4x4's I may have overlooked. The Vitara may yet be narrow enough if I can ditch the center console. Compact trucks got too wide for what I'll call "close buckets" but are too narrow for a good center seating position in a bench, so it is full size or compact, unless something interesting I don't know about turns up. EV's don't yet have low range (that I know about, or isn't a $50k custom), there is no bus, and a bicycle just won't work with having to get the kids on the school bus and getting to work on time. Please keep coming up with suggestions!