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I'm not the thread owner but am currently in process with Drew to get a slide in shell built, and I have to say he has been great to work with.

What??? Don't build an overland truck? After a few years the pain will fade, then if you're really nuts you'll sign up to build a second one (well we are....). I need to get my head examined. Oh, and while building ours I thought that the box would be all square angles, so easy. But everything...

I think that might work. There's cylindrical silencers available, if I sleeved it over some exhaust wrap it might work well. Thanks for the idea.

Well, the "Build from a Distance" is progressing. @Bison Overland Campers has let us know the extrusions have been cut and the panel design is with the panel manufacturer. And our window placement and order has been finalized. I'm actively watching for any sales on the gear we will be needing to...

Although you said no wood, this is what we did in the truck in our avatar. The entire shell is foam cored composite. For most of the interior structural walls we used 30mm honeycomb cored composite panels. Super light and very strong. For most of the remaining it was mostly baltic birch 1/2" ply...

Well quick update. Our new to us F350 was delivered to my mother's house in Florida. She reports that all looked good and one of her neighbors who is familiar with trucks says it looks good. Good to know it is there and waiting for us for when we arrive back to the USA. But even more exciting...

Not sure when this all started. I have had the truck in a few different shops over the last few months. One of them I even had 2 mechanics just looking around for problems. They did find a loose front engine mount then. We go in on Friday for a possible clutch replacement and transmission check...

We'll be there soon. But lookout for a new truck! We finally decided to bight the bullet and buy a camper that will stay in the USA. We're planning on having this truck outside of the country for the foreseeable future and since we don't own a house... Though since I'm not right in the head it...

Hey all, been a while and a lot has happened. We're still bouncing around South America and are currently in Santiago Chile. We've been having a blast but the truck continues to cause us troubles. We're now "camped" in a campground with the transmission mount off to a welding shop and a log...

Well I ended up settling on some 50 am Anderson plugs. I found these 3D printed covers on eBay for them. Plan is to mount one on the side of the footwell of the slide in camper and one on the truck bed. Then a jumper cabler between the 2. Although we have yet laid our eyes on our new to us...

Hi all, since our current expedition truck is now in South America and will be outside of the USA for the foreseeable future we decided to get a second smaller camper for our visits back home. Never thought we would build out a second camper but after looking at our options we decided that we...

Thanks for the advice, we ended up putting a deposit on the Bison. Now we need to get busy finding a truck. Maybe we could find a decent F350 with a steel bed already installed.

Hi all, a few years back we built a Total Composites habitat for our Mercedes 1120AF. We moved off a sailboat directly in the truck, which is our 1 and only home. Well, our home has left North America for several years (we're currently in Chile), so we're thinking we need another summer home in...

Looks great! Although I never thought I would ever say this, we're seriously considering building a second truck camper (our first is our current home, a Mercedes 1120AF with a Total Composites box that we're currently traveling in Chile with). This second truck would be for our 2-3 months...

Yup, it shouldn't have moved. The mechanic didn't find anything that would have caused it. I asked about using bearing loctite but he didn't seem to think it was necessary. The main one that failed, the machine seat isn't 100% contiguous. There's cutouts for oil channels, leaving a paper thin...

The repair has been going fairly smoothly (finding parts here is a challenge). The transfer case came out, taken apart and all parts cleaned and the source of the metal found. Each of the 3 shafts within the transfer case are adjusted within the case shells with these very thin washers. These...

And the latest on the transfer case boondoggle. The Mercedes dealership has now refused to work on the truck as parts are not available for it in Chile (and this is the dealership that controls all of Chile, they have the entire country). So now we are off to a small independent mechanic shop...

Yup, Kaufmans is where we are scheduled. Can't get either case gaskets or seals from them. That's the parts we have on order in Ushuaia. Kaufmans is the one that told me the 1.5 months for any parts. They plan on cutting paper gaskets from sheet, putting in inexpensive aftermarket seals...

Well I think that these parts are now in short supply. I doubt some are still being manufactured. And yeah, the truck was pretty trouble free for a few years. Now it seems to be going through a rough patch. Hopefully on Monday I'll have better news to share. When we were still sailing, we all...

Thanks for the offer, biggest hurdle though is getting parts through customs here. Well, I'm got my fingers crossed it's a bearing, which I can source here. Second plan is to buy a complete used box in Europe, but have the seller open it up and just mail me the bits I need instead of a pallet...