In this experimental investigation, the authors have fabricated and characterized composites made from pyrolysis oil rubber and epoxy resin. As the dumping of waste scrap tires poses a serious environmental threat, the pyrolysis oil rubber was extracted from these waste tires only. The prepared blend having pyrolysis oil with various weight percentages (wt%) was examined on the basis of various physical, microstructural, mechanical, and thermal tests. The microstructural tests (scanning electron microscopy and X-ray diffraction) analysis complemented with the mechanical tests (tensile, compression, flexural, hardness, and impact) results and confirmed that the 4.4 wt% of pyrolysis oil in epoxy resin sample exhibited the best results in toughening of the polymer network. Furthermore, the thermal analysis (differential thermal analysis and thermogravimetric analysis), electrical conductivity, density, water absorption, gas chromatography-mass spectroscopy, and Fourier-transform infrared tests for the composites were also performed. Low density and high tensile strength than neat epoxy resin makes this composite a potential candidate for fabricating lightweight structures and in polymer coatings for automotive industries. POLYM. ENG. SCI., 2019. (c) 2019 Society of Plastics Engineers