Exploring Options for an Expedition Vehicle for Global Travel

[Sailmike]

Over the last 4-5 years I've been doing a lot of car camping with a tent. I found that I absolutely love that lifestyle. So much that I now want to do that full time. Next fall I hope to purchase either an F150 or F250. The MPG of the F350 to F550 is so bad that I wouldn't be able to travel far with my budget. I'll be building the camper on one of the F series trucks from scratch. There's so much that I need to learn, which is why I'm here. I've got my eye on these two options:

I can't afford the EarthRoamer, but I'd love to build something similar to that. I'm thinking of taking a welding class so I can do the aluminum frame. From what I've read on this forum, it seems that the whole shell can be built entirely of fiberglass sandwich panels? There's so many questions. What would it take to build one of these? I do have experience with fiberglass and I think that would be fairly easy to work with.

1. For the first option, the bed can flex quite a bit. Would fiberglass sandwich panels be able to handle that flexing?
2. Are fiberglass sandwich panels alone strong enough for the cabover bed?
3. I would need to walk on the roof for any needed repairs and/or installations. Are those panels strong enough for that?
4. For the EarthRoamer type vehicle, are the fiberglass sandwich panels strong enough to use for the floor? Or does there have to be some aluminum frame to help support it?
5. Would either of those options be difficult to make street legal? Insurance via USAA?
6. For the EarthRoamer type vehicle, how would the whole thing attach to the frame of the truck?
7. Would it be light enough for the truck to handle the load?
8. How hard is it to install those tires and the suspension to match? How much would it cost to have someone do those upgrades for me?
9. Do the tires and suspension negatively impact the mileage much?

I'm sure there will be a billion more questions, especially when construction begins.

Thanks a lot,
Mike

 

[nickw]

Over the last 4-5 years I've been doing a lot of car camping with a tent. I found that I absolutely love that lifestyle. So much that I now want to do that full time. Next fall I hope to purchase either an F150 or F250. The MPG of the F350 to F550 is so bad that I wouldn't be able to travel far with my budget. I'll be building the camper on one of the F series trucks from scratch. There's so much that I need to learn, which is why I'm here. I've got my eye on these two options:
View attachment 532848View attachment 532849
I can't afford the EarthRoamer, but I'd love to build something similar to that. I'm thinking of taking a welding class so I can do the aluminum frame. From what I've read on this forum, it seems that the whole shell can be built entirely of fiberglass sandwich panels? There's so many questions. What would it take to build one of these? I do have experience with fiberglass and I think that would be fairly easy to work with.

1. For the first option, the bed can flex quite a bit. Would fiberglass sandwich panels be able to handle that flexing?
2. Are fiberglass sandwich panels alone strong enough for the cabover bed?
3. I would need to walk on the roof for any needed repairs and/or installations. Are those panels strong enough for that?
4. For the EarthRoamer type vehicle, are the fiberglass sandwich panels strong enough to use for the floor? Or does there have to be some aluminum frame to help support it?
5. Would either of those options be difficult to make street legal? Insurance via USAA?
6. For the EarthRoamer type vehicle, how would the whole thing attach to the frame of the truck?
7. Would it be light enough for the truck to handle the load?
8. How hard is it to install those tires and the suspension to match? How much would it cost to have someone do those upgrades for me?
9. Do the tires and suspension negatively impact the mileage much?

I'm sure there will be a billion more questions, especially when construction begins.

Thanks a lot,
Mike

Mike, I'd go F250 with a commercially available camper, like the Four Wheel Camper. What is your budget? I'm guessing new regular cab long bed F250 + new FWC can be had for around $65k all in. Call it $70k with a few goodies.

 

[Sailmike]

I’ll be getting a used F250, because I won’t have enough for a new one. Then that won’t leave enough for a slide in camper. Building one appears to be my best option because I can buy supplies for it on a monthly basis. It’ll be a bit of a slow build, but, if anything breaks, I’ll know how to fix it.

 

[Peter_n_Margaret]

Fibreglass/closed cell polyurethane foam/fibreglass sandwich panel glued together with Sikaflex 252 is the way to go.
Incredibly strong, superior insulation great durable finish and easy to work with. No special skills required.
This company in Australia will cut all the panels to shape and rebate the edges, window holes all cut out etc, etc to +/- 0.1mm from cad files, then it simply glues together like IKEA flat pack furniture. Maybe someone there does something like this? http://vanglass.homestead.com/index.html
Roof strength? Makes a great viewing platform - 6 people no problem.

Cheers,
Peter
OKA196 motorhome

 

[Peter_n_Margaret]

I built mine in 2004/5. It is sandwich panel over a light steel frame, which generally was not needed.
This one was a fairly quick build and frameless. http://epicycles.com/
This friend had more time than money and manufactured his own panels, vacuum bagged on the shed floor. It took him 2 years to build, was completed in 2010 and is a work of art from a finish perspective. Shower and toilet, solar, bed-over-cab.

Despite appearances it is actually a Defender (with a Challenger cab). The "house" is glued to the cab with Sikaflex and the sandwich floor (with heavier glass) is glued to rubber strips which are glued directly to the vehicle chassis. There is no steel involved.

We owned a 1987 F350 4WD motorhome for 12 years and when we needed to replace it (after the chassis cracked 6 times) I expected to replace it with a new F250. After a good look, I came to the conclusion that they were simply not tough enough and were not suitable for tough bush work, so we bought the OKA and never looked back. Second choice would be an NPS or Canter with super single wheels and parabolic springs.
Cheers,
Peter
OKA196 motorhome

 

[The Artisan]

Fibreglass/closed cell polyurethane foam/fibreglass sandwich panel glued together with Sikaflex 252 is the way to go.
Incredibly strong, superior insulation great durable finish and easy to work with. No special skills required.
This company in Australia will cut all the panels to shape and rebate the edges, window holes all cut out etc, etc to +/- 0.1mm from cad files, then it simply glues together like IKEA flat pack furniture. Maybe someone there does something like this? http://vanglass.homestead.com/index.html
Roof strength? Makes a great viewing platform - 6 people no problem.
View attachment 532971
Cheers,
Peter
OKA196 motorhome

I will be offering something like this in the near future with a hardsided poptopper.
4 foot down to 8 foot up. Or other configurations. Depends hot high you want the lower pod. Doing this design for 2 reasons. 1 keep the profile low and 2 less surface area means less chances of delamination down the road.
Build your own shell as you described
Kevin

 

[Cackalak Han]

I haven't been off continent (HI doesn't really count) but for covering the overwhelming majority of the 3 North American countries if I was going to try to fulltime it I'd be trying to stay as light and maintenance free as possible.. like to the point of looking at figuring out 20mm of lift and a sump guard under an AWD Toyota Sienna.

The two 4wd vehicles I have now are just plain overkill in terms of traction and brute strength.. it's nice to have but then I'm stuck getting 20mpg on my best tanks and thinking "I didn't do a single thing in the last 5000 miles I couldn't have done in a Subaru" .

What I find most welcome in an all terrain touring vehicle is being able to prepare simple food (coffee, cereal..) inside when weather or insects make outdoor eating miserable, the ability to stealth sleep for quick overnights without planning and some quality non-glare, long distance lighting up front that doesn't flood the near field too much. The hardest one of those to satisfy on a small efficient vehicle is indoor food prep because it takes stable, comfortable room.

I think the largest vehicle I'd consider would be a reg cab, 8' bed half ton pickup. Any bigger and the size starts to be a handicap.

With a lift and larger tires on an AWD Sienna, you're not getting any better than 20mpg. Stock, they're 23mpg highway.

I would echo a truck as the best, but I would say a mid-size like a Tacoma or Ranger with a high-rise shell.

 

[Victorian]

If you are thinking of global travel, I would skip the Ford idea or anything made in North America. You will have a tough time finding mechanics and parts. I recommend sourcing a Mercedes G wagon cab chassis to stay within the pick up size. Mercedes is the only manufacturer that has a global support net work.
And yes composite panels are strong enough for a cab over.

 

[Sailmike]

All of my long camping trips have been in an AWD Honda CRV. This car did very well on all the roads I tackled, but there were some roads where I'd prefer a much more rugged vehicle. Sometimes I had to stop and get out to move a rock out of the road. For the Dempster Highway in the Yukon for example, I would be more comfortable with a more rugged 4WD. I had to drive the Honda through about 100 miles of mud! Some of the campsites I visited were a tight fit even for a Honda CRV, but the vast majority had spots roomy enough for a 20' to 25' RV. I would just park in a roomy spot, get out, and hike around to the campsites to find one that'll fit and to check the roads leading to them.

Peter, that's almost exactly what I'm thinking of doing. I love the rounded corners. I don't know about gluing the camper to the cab though. With all the flex that'll happen, that seems like a bad idea. Has that been a problem? Any issues with the street legality and getting insurance? Do you have any photos on the camper to chassis joint? I assume those spare tire holders commercially available?

Victorian, I've pretty much got my heart set on the F250. Perhaps, I could just plan ahead and look for places I can source parts for the F250? I know enough to do my own brake maintenance. Just looked up the Mercedes G wagon, and whoa those are pricey.

Mike

 

[Peter_n_Margaret]

Peter, that's almost exactly what I'm thinking of doing. I love the rounded corners. I don't know about gluing the camper to the cab though. With all the flex that'll happen, that seems like a bad idea. Has that been a problem? Any issues with the street legality and getting insurance? Do you have any photos on the camper to chassis joint? I assume those spare tire holders commercially available?

The sandwich panel body actually provides torsional strength to the chassis. It is 9 years old and no problems. No other pics, sorry. He used a local auto engineer for the approvals and had no problems. It is ALL self built. Lots of hours in those rounded corners and things like the recessed awning.
I would not choose an F250 either. Toyota Landcruiser Troopy or cab chassis.
Cheers,
Peter

 

[nickw]

If you are thinking of global travel, I would skip the Ford idea or anything made in North America. You will have a tough time finding mechanics and parts. I recommend sourcing a Mercedes G wagon cab chassis to stay within the pick up size. Mercedes is the only manufacturer that has a global support net work.
And yes composite panels are strong enough for a cab over.

Domestic rigs work just fine for global travel, particularly the Fords:

Turtle Expedition

turtleexpedition.com

Gwagens are not well supported here in the states and if you can find a good one, they are $$.

 

[nickw]

Here is a cool option too:

Tall Commercial Truck Caps | Service Bodies For Trucks | Diablo

Our Diablo model slide in service body is the largest mobile workstation for professionals, to safely store tools and equipment. Order today!

www.spacekap.com

Member on Expo:

The Grand Terrainer: 2017+ Ford F-250 and SpaceKap Diablo 8'

This is a long overdue rig project posting of a 2017+ F250/SpaceKap Diablo 8’ camper conversion! The genesis of the project was the desire to build a full-time luxury overland vehicle...on a reasonable budget and timeline! I previously owned a Jeep Patriot Trail Rated with Autohome Columbus...

expeditionportal.com

I've seen a couple for sale around the $10k - $11k range (if you can find it) and slap it on a used F250....

What is your budget?

 

[Sailmike]

I’m thinking that the F250 looks like a good compromise between mileage and payload capability. I also notice that there’s only a 1 MPG difference between the F250 and F350.

My budget for truck and camper will be around $30k-$40k. I won’t know till next fall. That Diablo looks pretty cool.

 

[shade]

Will you be traveling solo the majority of the time? My small truck & camper (Toyota Tacoma & GFC) are considerably more luxurious when solo. Adding a second person eats up a lot of sleeping and cargo space when using a smaller platform.

 

[Victorian]

Domestic rigs work just fine for global travel, particularly the Fords:

Turtle Expedition

turtleexpedition.com

Gwagens are not well supported here in the states and if you can find a good one, they are $$.

Again, I was responding to global travel. The fords, Chevy and others are ok as long as you stay in North America. As soon as you hit europe, Asia or Africa you are on your own. I'm sure there is a shop somewhere with a mechanic that "could" help. But how far away are they and how do you get there in case of a breakedown? I had a major breakdown in the middle of the Sahara and need to find transport to the next big city (Dakar Senegal). It took me 2 months to get parts and countless expensive internal phone calls till it was drivable.
Good luck!