This paper describes the designing and manufacturing process of a complex special utility vehicle (SUV) using the methodical design approach for which the basics were explained decades ago in Germany. The application steps of the design methodology with comprehensive data are clearly outlined and the experiences gained during the project along with the authors' experiences in design research and design practice over 25 years are generously shared. This paper contributes to the methodical approach laid by Pahl & Beitz with an industrial example proving its applicability in real engineering design applications. The proposed solutions for difficulties encountered in the process are especially valuable and applicable for SMEs (small and medium-sized enterprises) in the field. Such details are reported with comprehensive discussions in this paper.