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Who manufactured your current hatches and windows?

At over 9 tons and 27' long our MB917AF went pretty much anywhere we wanted. The 917 has a very tight turning circle (tighter than a pick up truck) to turning around was rarely a problem. I would not want to go any bigger though.

You will use the winch, but not for yourself. We have pulled out uncounted vehicles.

We have run a Stirling for 8 years no issues. Defender Marine was the supplier. https://www.sterling-power-usa.com/SterlingPower24volt-to-24volt-dc-to-dc-batterytobatterycharger.aspx

Your biggest problem will be the dogs. Vet certificate, then government office approval, before every border crossing. PITA. Check out Wicked Campers Patagonia, 2wd POS all over the place, rarely stuck.

You will have no trouble at all traveling The Pan Am and associated routes. You may have to give up some very remote trips but on the whole no problem at all.

Look for all position, on/off road tires for the logging and construction industries.

Krown https://www.krown.com/en/products/aerosols/rust-protection-lubricant/ https://www.peaveymart.com/automotive/oils-additives/spray-lubricant/379l-fluid-film-rust-corrosion-protection-lubricant/13402?sourceCategoryCode=153 https://www.woolwax.ca/

A couple of observations: A reefer box is a good start, if it can be customized, double rear doors will be a disaster. Composite panels are the way to go, home made usually look like home made, professional suppliers are the best option. Any "living space" in the cab is outside the heated...

Any rubber or sealant coating works well until it is compromised, then it seals water in instead of out. Oil and wax based undercoating creeps and heals displacing water. It requires yearly recoating but does a better job.

1st owner put them there, they were the first thing I removed.

Alignment is very possible and can be done by most truck tire shops, just like a car but bigger! Bad shocks will also wear tires quickly( I know you have new shocks)385/65r22.5 is another good choice.

22.5"s air down too. We regularly aired down to 50psi from 95psi for washboard. There is some confusion over "super singles". Super singles are a super wide tire that replace duals for on road use. When the Super Singles name crops up in the overland world what we are talking about are singles...

The 20" rim is a better off road option as you have a higher sidewall, so deflating gives a longer contact patch. 20" tires are not sold in South America. If South America is on the plans stay with the 22.5 rim. We had 315 80 22.5 all round, readily available worldwide but a bit narrow for sand...

Tents suck. They are cold and have major condensation issues, their best point is they are light. If I have to carry it multiple miles into the back country, then a tent is the way to go. If I have a vehicle why put up with the discomfort? I would not even consider a pop up.

correct

2.5 gallons might not seem like much but used carefully that could be 5 or 6 showers!

Nice, the trouble is you will pay 25% duty on a truck chassis as opposed to 2.5% for a motor home or 0% for a fire truck.

The climbing world, the rigging and rescue world, the world selling static and dynamic rope.

Not climbing rope, although I do use old climbing rope for tie downs. Static rope does not have the massive stretch that climbing rope has. Nylon static rope is used as mooring lines or used by arborists etc. It is very strong and has some give. 1" braided sheath is plenty strong, I carry 150'...