New Camper Build Planning - Considering NPR (USA) - Feedback Welcomed

luthj

Engineer In Residence
Greetings,

The wife and I have done a fair bit of overland travel over the years (Aus, NZ, Central America). Started in a tiny VW camper, currently in a 140WB T1N MB sprinter. The sprinter has has served us well for the last 10 years. The buildout and drivetrain are mostly custom at this point. It meets most of our needs quite well, but has a few issues that really can't be resolved on that chassis. Our family may be getting a third, and as I get older, I want a touch more comfort when we are on the road for years at a time.

Specifically we need more space, and I would really like a vehicle that we can keep cool, in 90F/32C+ weather off the grid.

I am still in the early planning stages, going through floor plans, chassis, etc. As with many, I see the advantages of a medium truck platform. Payload, turning circle, reasonably heavy suspension/drivetrain. Putting a 12-13.5' composite box on a 12-14klb GVWR chassis seems like a pretty good compromise. We would likely be using this vehicle for long term international travel for about 10 years on and off. This probably will include a few RORO shipping events, etc. The plan would be as low a profile composite box as reasonable, and try to stay under 22ft length. We can handle the build-out, etc. I am a passable fabricator, but don't have a big shop anymore. I don't relish the idea of manhandling 400lb axles around to DIY a conversion.

I don't want to give up 4WD. I also require low range, or at a least a semi decent crawl ratio otherwise. The more recent Fuso platform doesn't offer low range in the USA, and the duonic trans gives me a bit of heartburn.

The newish NPR seems like it could be a good fit. Single cab with a center seat in our case. It would need converted to 4x4 though. As far as powerplants go I would love some feedback. I have no problem with used trucks, and would probably target a lightly used unit to keep my costs under control.

Powerplants:
  • The 5.2L I4 diesel could work. Any experience with reversible DPF/SCR bypass for operation outside North America?
  • 6.0L gas is a fairly well know powerplant at this point. Fuel economy is going to be pretty poor.
  • 6.6L gas unit is fairly new, but does appear to have somewhat improved fuel economy, and the output is quite nice...

I am curious what vendors offer 4wd conversions? I see that Ridge Rock advertises this service (about $35k?). Not sure what that all includes, and they have sparse details, or even good technical photos. I don't need the ultimate super ride overland mega package, or whatever. Decent ride, 34-37" super singles, and low range will meet my needs fine. Modest improvement in ground clearance would be nice.


Anyways, general feedback on the platform, or related suggestions are welcome. I should mention that we are not ultra wealthy, just engineers with excellent planning skills. My goal would be to do something in the $170k USD range, and expect the project to balloon to about $200k with the typical overruns, and the "might as well while I am in here" stuff.
 
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luthj

Engineer In Residence
A really quick sketch/model on the 132" WB. 37" tires and a 3" lift. Obviously that is the most recent body style, as that was what I could find in a brief search. 15ft interior box is a bit excessive, but a place to start. 22.5' overall length is a bit more than I want.

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