rruff
Explorer
I agree, you don't need an articulating subframe on your rig.
If it's 10' long behind the cab, that's pretty far aft compared to the 6.75' bed. EDIT: Nevermind, I guess it comes with an 8' bed.
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F450 Custom Composite Expedition Truck - ALL THE DETAILS
- Thread starter Allysonoverland
- Start date
If it's 10' long behind the cab, that's pretty far aft compared to the 6.75' bed. EDIT: Nevermind, I guess it comes with an 8' bed.
EpicPlanet
Member
@Allysonoverland Love the thread and how clearly you're articulating the reason behind your decisions. I'm looking to drive the PCH this summer. Later on, through to Argentina and, hopefully, Antarctica. Looking forward to seeing your build!
rruff
Explorer
Are you going to start a thread? Just curious, not pressuring... hell, I never made a thread about mine...
Allysonoverland
Member
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.
Allysonoverland
Member
Let’s talk about overland flatbeds, flat beds, trays, camper trays, whatever you want to call them! Because steel adds a significant amount of weight, I am only going to be discussing aluminum options here...
When sourcing a flatbed for your expedition build, one of the most critical yet often overlooked factors is deck height - that is, how high the bed sits once mounted on your truck chassis.
Custom-built beds typically allow for a lower deck height, which not only improves stability by keeping the center of gravity (COG) closer to the ground but also reduces the overall height of the rig. This lessens the risk of running into low hanging branches on trails, or your rig being too top-heavy (which is not safe on super rugged terrain).
Many mass-produced flatbeds, while much more affordable, are designed for versatile fitment and to clear most wheels, and sometimes use thicker joists, resulting in a taller profile and higher COG. Just something to keep in mind when comparing pricing!
___________
In the 2025 Overland world, I think Bowen Customs is kind of considered the gold standard of flatbeds. They have one of lowest deck heights, high quality craftsmanship and excellent aesthetics. However, as with all good things, this comes at a premium price. I'm not knocking Bowen - there’s obviously a reason for their extended lead times and long wait list!
However, ultimately I decided that I have financial goals beyond just owning a BA camper - and can think of a LOT of ways to spend $25,000+ … so I set off to find more affordable alternatives. Let's talk about them!
NOTE: At time of writing this, it’s April 2025 and we are currently seeing a shift in global trade policies. Pricing is changing rapidly. Each vendor also offers various sizes / specs so a true apples-to-apples comparison is quite difficult. But for the purpose of this thread, I will try to keep the estimates relative to a base model 8 ft aluminum flat bed.
So - in order of least expensive to most expensive (based on previous quotes or available internet information), here’s a list of aluminum flatbeds / fabricators you could consider for your expedition truck.
Option #1 - Mass Available / Manufactured
These beds are typically made for commercial use and as mentioned at the beginning of this post, often have a higher deck height. They usually offer various “service body” options for storage but imo those are quite bulky and likely not something I'd want on an off-road vehicle.
Hillsboro
Est. base price: $4,100ish for a basic deck, no underbody storage boxes
Location: Hillsboro, Kansas - available through distributors
CM Bed
Est. base price: $4,500 - $6,000 for a basic deck, no underbody storage boxes.
Location: Oklahoma - widely available through distributors
Other beds that seem to fall into this category, but I do not have details on:
Aluma
Knapheide
+more
Because these simple flat decks are generally the most budget friendly choice and "off-roading" customizations are limited - other Expo Portal members have resorted to heavily modifying them after-market with the help of their local fabricators.
Here are some under body storage solutions I've seen for these decks:
-Bolting standard buyers boxes or similar, directly to the deck.
-These tapered boxes from Australia
-Stable Camper has designed tapered tool boxes that are compatible with CM beds (+$6,000)
-Hiring a local fabricator to make you custom boxes/ add ons
Option #2 - Semi-Custom or Fully Custom
These flatbeds are usually built with overlanding in mind, and depending on tire size, can be customized to allow for a lower deck height that stock beds. The boxes for storage are often tapered to be less bulky and provide better clearance.
Alum-Line
Est. base price: $7,500 with custom underbody boxes
Location: Iowa
Custom options: Fully customizable sizing, with custom boxes, optional bedliner coating, head ache rack delete, custom flares
Intercontinental Truck Body
Est. Base Price: $12,000? USD with custom underbody storage boxes
Location: Canada
NOTE: I am putting this here because at one point I had ITB quote me a full aluminum box + flatbed after learning they fabricate the GRID trucks. Their pricing was quite reasonable for the project but I went a different route due to lead times. Unfortunately, I never asked for just a flatbed quote. Looking back at the quote right now, I feel as though the flatbed would fall into the $12,000 range but it could be less/more.
Custom options: ITB seemed to be fully customizable in all aspects and will make you a variety of things.
Overland Explorer Vehicles
Est. Base Price: $12,150 USD with underbody storage boxes
Location: Canada + network of USA distributors
Custom options: Spare tire storage box or “garage”, powder coat, folding stairs, + more. Max length appears to be 9 ft and does have some weight restrictions.
Mits Alloy
Est. base price: $14,000 USD with custom underbody boxes and black powder coat
Location: Australia with USA distributors
Custom options: Rear under tray drawer, spare water tank, toolboxes, textured powder coat, flared mudguards. Max length appears to be 8 ft
Summit Expedition Trucks
Est. base price: $15,100 USD with custom underbody boxes
Location: Canada
Custom options available: Lots of sizes / styles to choose from. Head ache rack delete, accessory rear drawer, spare water tank, etc. Max length appears to be 9 ft. One concern is their website notes some limitations on the fenders for larger 40” tires - worth asking about.
Nuthouse Industries
Est. Base price: $18,000 with tapered underbody storage boxes/powder coat
Location: Ohio
Customization options: various sizes, tapered underbody storage boxes, skirting, side rails, gates, black powder coat, ramps, canopy, headache rack “garage”, etc
I don’t have current pricing info for:
Highway Products
Location: Oregon
Sherptek
Location: Oregon
But to my knowledge, these are premium fully custom beds. Based on forum discussion, get the impression they would fall somewhere in here for pricing.
Bowen Customs
Location: Colorado
Est, Base price: $25,000 with under Body storage boxes
Custom options: removable tailgate, auxiliary water tank, custom powder coated colors, articulating subframe, internal tie downs + more.
And finally, other options I’ve ran across that I don’t have any pricing / detailed info on:
Protech
Mountain Guild Upfitters
Next jump outfitters
Norweld
Ute Bed
_________________________________________
As for me… Revisiting this list was good to consider all my options again. I had a deposit down, and was working with a builder in Canada, but due to some changing timelines and the current tariff situation, things are kind of up in the air at the moment. If all goes according to plan, the camper interior is expected to be done end of May / early June and I will need a bed to pick it up. So a final decision must be made & posted here very soon.
When sourcing a flatbed for your expedition build, one of the most critical yet often overlooked factors is deck height - that is, how high the bed sits once mounted on your truck chassis.
Custom-built beds typically allow for a lower deck height, which not only improves stability by keeping the center of gravity (COG) closer to the ground but also reduces the overall height of the rig. This lessens the risk of running into low hanging branches on trails, or your rig being too top-heavy (which is not safe on super rugged terrain).
Many mass-produced flatbeds, while much more affordable, are designed for versatile fitment and to clear most wheels, and sometimes use thicker joists, resulting in a taller profile and higher COG. Just something to keep in mind when comparing pricing!
___________
In the 2025 Overland world, I think Bowen Customs is kind of considered the gold standard of flatbeds. They have one of lowest deck heights, high quality craftsmanship and excellent aesthetics. However, as with all good things, this comes at a premium price. I'm not knocking Bowen - there’s obviously a reason for their extended lead times and long wait list!
However, ultimately I decided that I have financial goals beyond just owning a BA camper - and can think of a LOT of ways to spend $25,000+ … so I set off to find more affordable alternatives. Let's talk about them!
NOTE: At time of writing this, it’s April 2025 and we are currently seeing a shift in global trade policies. Pricing is changing rapidly. Each vendor also offers various sizes / specs so a true apples-to-apples comparison is quite difficult. But for the purpose of this thread, I will try to keep the estimates relative to a base model 8 ft aluminum flat bed.
So - in order of least expensive to most expensive (based on previous quotes or available internet information), here’s a list of aluminum flatbeds / fabricators you could consider for your expedition truck.
Option #1 - Mass Available / Manufactured
These beds are typically made for commercial use and as mentioned at the beginning of this post, often have a higher deck height. They usually offer various “service body” options for storage but imo those are quite bulky and likely not something I'd want on an off-road vehicle.
Hillsboro
Est. base price: $4,100ish for a basic deck, no underbody storage boxes
Location: Hillsboro, Kansas - available through distributors
CM Bed
Est. base price: $4,500 - $6,000 for a basic deck, no underbody storage boxes.
Location: Oklahoma - widely available through distributors
Other beds that seem to fall into this category, but I do not have details on:
Aluma
Knapheide
+more
Because these simple flat decks are generally the most budget friendly choice and "off-roading" customizations are limited - other Expo Portal members have resorted to heavily modifying them after-market with the help of their local fabricators.
Here are some under body storage solutions I've seen for these decks:
-Bolting standard buyers boxes or similar, directly to the deck.
-These tapered boxes from Australia
-Stable Camper has designed tapered tool boxes that are compatible with CM beds (+$6,000)
-Hiring a local fabricator to make you custom boxes/ add ons
Option #2 - Semi-Custom or Fully Custom
These flatbeds are usually built with overlanding in mind, and depending on tire size, can be customized to allow for a lower deck height that stock beds. The boxes for storage are often tapered to be less bulky and provide better clearance.
Alum-Line
Est. base price: $7,500 with custom underbody boxes
Location: Iowa
Custom options: Fully customizable sizing, with custom boxes, optional bedliner coating, head ache rack delete, custom flares
Intercontinental Truck Body
Est. Base Price: $12,000? USD with custom underbody storage boxes
Location: Canada
NOTE: I am putting this here because at one point I had ITB quote me a full aluminum box + flatbed after learning they fabricate the GRID trucks. Their pricing was quite reasonable for the project but I went a different route due to lead times. Unfortunately, I never asked for just a flatbed quote. Looking back at the quote right now, I feel as though the flatbed would fall into the $12,000 range but it could be less/more.
Custom options: ITB seemed to be fully customizable in all aspects and will make you a variety of things.
Overland Explorer Vehicles
Est. Base Price: $12,150 USD with underbody storage boxes
Location: Canada + network of USA distributors
Custom options: Spare tire storage box or “garage”, powder coat, folding stairs, + more. Max length appears to be 9 ft and does have some weight restrictions.
Mits Alloy
Est. base price: $14,000 USD with custom underbody boxes and black powder coat
Location: Australia with USA distributors
Custom options: Rear under tray drawer, spare water tank, toolboxes, textured powder coat, flared mudguards. Max length appears to be 8 ft
Summit Expedition Trucks
Est. base price: $15,100 USD with custom underbody boxes
Location: Canada
Custom options available: Lots of sizes / styles to choose from. Head ache rack delete, accessory rear drawer, spare water tank, etc. Max length appears to be 9 ft. One concern is their website notes some limitations on the fenders for larger 40” tires - worth asking about.
Nuthouse Industries
Est. Base price: $18,000 with tapered underbody storage boxes/powder coat
Location: Ohio
Customization options: various sizes, tapered underbody storage boxes, skirting, side rails, gates, black powder coat, ramps, canopy, headache rack “garage”, etc
I don’t have current pricing info for:
Highway Products
Location: Oregon
Sherptek
Location: Oregon
But to my knowledge, these are premium fully custom beds. Based on forum discussion, get the impression they would fall somewhere in here for pricing.
Bowen Customs
Location: Colorado
Est, Base price: $25,000 with under Body storage boxes
Custom options: removable tailgate, auxiliary water tank, custom powder coated colors, articulating subframe, internal tie downs + more.
And finally, other options I’ve ran across that I don’t have any pricing / detailed info on:
Protech
Mountain Guild Upfitters
Next jump outfitters
Norweld
Ute Bed
_________________________________________
As for me… Revisiting this list was good to consider all my options again. I had a deposit down, and was working with a builder in Canada, but due to some changing timelines and the current tariff situation, things are kind of up in the air at the moment. If all goes according to plan, the camper interior is expected to be done end of May / early June and I will need a bed to pick it up. So a final decision must be made & posted here very soon.
Last edited:
Allysonoverland
Member
Yes, I'm pretty in the weeds of it now.
The custom camper shell was just delivered to Montana today! The interior starts next and a lot of the parts have been arranged already. Unfortunately, timelines have not gone completely to plan so I am doing the financially responsible thing and waiting for my van to sell before buying the truck - but with summer approaching, hopefully that happens very soon.
I am not buying new and have continued to check the used market, finding there are quite a few F450 pickups to choose from within my criteria - so I'm not too stressed...yet
SDDiver5
Expedition Leader
Exciting!View attachment 874966
Yes, I'm pretty in the weeds of it now.
The custom camper shell was just delivered to Montana today! The interior starts next and a lot of the parts have been arranged already. Unfortunately, timelines have not gone completely to plan so I am doing the financially responsible thing and waiting for my van to sell before buying the truck - but with summer approaching, hopefully that happens very soon.
I am not buying new and have continued to check the used market, finding there are quite a few F450 pickups to choose from within my criteria - so I'm not too stressed...yet
rruff
Explorer
You don't have universal fitment, but since your camper is flatbed style you'll have to clear the tires as well. You surely know this, but thought I'd mention it...
Agreed - the deck height is dictated by the size of your tires and your suspension up-travel, plus the need to clear various suspension bits, etc. You also have to accommodate the height of the truck cab and either add spacers under the box or raise the deck height such that the cabover will clear. An off-the-shelf or custom flatbed will have the same deck height assuming they have the same clearances for running gear.
Allysonoverland
Member
thank you both, I made some small edits to the post to hopefully clarify these points!
definitely an important detail to consider. my cab over height was originally calculated to eliminate unnecessary awkward space between it & the truck cab, while still mounting the deck as low as possible without voiding the option for larger tires if needed. with the hiccup in ordering my new flatbed, I suppose we will see how this pans out.
Will definitely address further in a future post about the shell / camper / truck dimensions!
rruff
Explorer
You mentioned this company, but I wondered if you asked about the 17" custom steel wheels?
If you go with LT tires, it looks like a good option for more meat on the tire, but 37s would be fine on 20" rims as well.
Steel Wheels | Stazworks
Steel Wheels for your rock buggies, snow crawlers, power wagons, and pavement princesses.
www.stazworks.com
Skinhyfish
Observer
Don’t use alumiline. Worst customer experience ever and list $7000 to them