F450 Custom Composite Expedition Truck - ALL THE DETAILS

[EpicPlanet]

Thanks for the kind words. Sounds like some epic plans. Antarctica is my DREAM destination...Are you going to post about your trips and if so, is there somewhere online I can follow along for these adventures?

Absolutely! At least, there will be. Haven't done much yet across socials and YouTube, but that's the plan. I'll let you know once there's something to see. Currently getting the vehicle ready. Not a live-in like this, but here's the thread.

2005 Gen 3 Montero (Pajero) Overland Build

Hello all. I recently bought a 2005 Mitsubishi Montero Limited with 134k miles for an overland build. Hoping to document the process here. It is currently completely stock. I did some light to moderate trails on the way home from buying it. Even in stock form, it was pretty impressive. I was by...

forum.expeditionportal.com

 

[Pundy]

This is a great thread, I love the detail and the research. I'm in the process of building up my truck as well, so am enjoying reading your thoughts. I am just about to get a tray bed built by Adam at Altra Fabrication. Just another thought for folks who are looking for a custom option, and one that is located on the east coast. https://www.altrafabrication.com/

 

[peculierboy]

We have a Sherptek bed system and couldn't be happier. The style/functionality isn't for everyone, but it works for us, and we were able to customize for our use. Ryan and his crew was awesome to work with and the detail/design was very nice. Not cheap, but things like on board air are integrated into the bed and easy to service. Chatting with someone about our bed at a rally, and they didn't like it for valid reasons, and I suggested they look at Bowen. Imagine my surprise the next year and he had one installed on his 5500 rig. I can comment on the build quality, (it was top notch), but some things were weird. Like the DEF filler was put on the right side, so he can't fill up at the same time. There were a few other things they (Bowen) did that they didn't consult on and the owner wasn't pleased. High quality for sure, but communication was not great. Like, told the install was a week, he dropped his truck off, and was told two weeks on arrival.

 

[Durango]

Thanks for some very impressive research!

In my two FWC flatbed builds in 2015 and 2018 I found the biggest challenge was finding a quality custom flatbed builder. (We even looked at making the 1000 mile trek to Iowa!)

But then serendipity struck 50 miles from our Durango, CO base with a custom fabrication firm for the oilfield industry. (After all, if your work can survive the rigors of the oil patch you're doing it right!)

Largo Tank in Farmington, NM did an impeccable job, (accurate to 1/8") on time and with great communication- at a very reasonable price on both of my builds. We've put 40,000 miles over VERY rough terrain on their latest Ram C&C 3500 flatbed and it has been perfect!

I honestly would drive 1000 miles to have Largo Tank do my next custom aluminum flatbed. (If you call ask for Adam.)

 

[Allysonoverland]

This is a great thread, I love the detail and the research. I'm in the process of building up my truck as well, so am enjoying reading your thoughts. I am just about to get a tray bed built by Adam at Altra Fabrication. Just another thought for folks who are looking for a custom option, and one that is located on the east coast. https://www.altrafabrication.com/

These look really nice! Thank you for posting! Any chance you’d be willing to share where they fall in terms of pricing?

 

[Pundy]

These look really nice! Thank you for posting! Any chance you’d be willing to share where they fall in terms of pricing?

Adam has pricing that he can share with you. The beds are pretty modular, and it's all based on the options that you want. I can tell you that mine will be more than $10,000 less than the quote that I got from Bowen. I also didn't need the extreme departure angle that Bowen beds allow, so I'm psyched to be able to have more customization to allow more room in the back hatches.

 

[breden487]

Thanks for your comments about the COG, this certainly makes logical sense. Given that explanation, you're right that I should be well within the limits of LT tires on the rear axel. I will probably still wait to weigh before investing in the wheels, but definitely feel better to think I can still more than likely go with LT tires as originally intended. The weight just seems to creep up as the build continues lol.

As for the crew cab - I am planning to remove the 60 from the 60/40 rear seat to make an aluminum platform for my dog with storage underneath. It will have a cozy padded topper and some pull out stairs to help him load easier as he ages. Obviously, the more storage the better but coming from a 144" sprinter, this rig will already have WAY more space than I know what to do with so I plan to keep one rear passenger seat for friends for now. 😊


Thanks for the kind words. Sounds like some epic plans. Antarctica is my DREAM destination...Are you going to post about your trips and if so, is there somewhere online I can follow along for these adventures?




I am so glad you all are enjoying the thread! I really hope to make this a resource for those who don't have the capacity to dive so deep into each topic.

@breden487 are you doing a 550 c&c or 450? sounds like a fun project. I agree - you need to start a thread! Love seeing the innovative ideas people come up with in these builds.

I have a new 450 can and chassis. Newest rev. of the OEV tray on order due first of June.

I'll start a thread, but surely mine isn't going to be as cool as yours! 😂

 

[Andrew_S]

I really enjoyed reading this so far, can't wait to see the next progress pics. It's great to see your thought process and rational. We are currently embarking on a project encompassing a few of these items, singles, flat deck and custom camper.
I'm torn on the composite vs full-frame aluminum camper- no pun intended. I can definitely recognize the benefits of a composite build but I struggle with the durability question mark when it comes to sustained offroading and chassis twisting drainage ditches.

 

[rruff]

I can definitely recognize the benefits of a composite build but I struggle with the durability question mark when it comes to sustained offroading and chassis twisting drainage ditches.

Yikes... no stiff shell is going to like that. Just make a pivoting bed, and no worries.

I used Energy Suspension poly isolators to make a pseudo 3 point, with actually way more than 3 points of support. Easy to spread the load. Front ones wide, and the rest on the centerline. They are ~$17/ea and I'd recommend ~400 lbs of static loading per, so if your flatbed is supporting 5k lbs you'd want 12+ of them.

 

[gator70]

You don't need a flatbed and some are very expensive. You can build a subframe for much less that is stronger than a flatbed.

 

[rruff]

^ True, but I wouldn't do it like that...

 

[Trail Talk]

I can definitely recognize the benefits of a composite build but I struggle with the durability question mark when it comes to sustained offroading and chassis twisting drainage ditches.

I’m returning to one of those chassis twisting trails this spring and am considering disconnecting the swaybars as a temporary assist.

 

[rruff]

I’m returning to one of those chassis twisting trails this spring and am considering disconnecting the swaybars as a temporary assist.

Your rig has some sort of pivot doesn't it? Disconnecting the swaybars might help a little, but the chassis will still "want" to twist a lot if it's open C.

 

[Trail Talk]

Your rig has some sort of pivot doesn't it? Disconnecting the swaybars might help a little, but the chassis will still "want" to twist a lot if it's open C.

Too true. All those tripod moments have me wondering how much it might help, will report back somewhere on the forum.

 

[rruff]

Any photos of what your mounting looks like? Pretty standard 3 point with pivot in the rear, or something else?