4 years later: My custom F-550 overland truck build is finally [off] road ready... The highs and lows of a composite truck camper build.
Posted by mwtownsend@reddit | overlanding | View on Reddit | 127 comments
Almost 5 years ago, I came across a home-built expedition vehicle / overland truck camper on a road trip (u/andrewmuse: this is all your fault), and I couldn’t stop thinking about it. I sold my product design company and went all in on building my own overland rig. My journey started on Reddit, so it felt like time to share an update here.
Broad strokes on the build:
- 2024 Ford F-550 Lariat diesel, 84” CA (19,500 GVWR)
- Full composite monocoque camper shell with custom 4-point subframe
- Finished weight, full fuel / no water: 15,260 lbs
- Front: 5,940
- Rear: 9,320
- Super single conversion (Continental 335x80r20) with no lift
- 95-gallon fresh water / 40-gallon grey water
- R20+ insulation
- R6 structural core
- R12 closed-cell spray foam
- R6 recycled PET acoustic panels + air gap
- EcoFlow power system with 800W solar and 10kWh batteries: this runs the refrigerator, fans, lights, etc. indefinitely
- Timberline 2.0 5kW diesel heater kept it warm in Colorado in February at 10,800 feet / 2°F
- Recycled PET wall panels
- Hi-Macs counters, backsplash, and shower pan
- Custom windows, which were probably my biggest mistake and definitely the biggest time sink
It’s been a really fun, really difficult truck camper build. Way more time, money, and problem-solving than I expected — but I’m getting excited to finally use it with my family this summer. I’m still debating whether to add exterior storage boxes. Right now I’m leaning no, but that could change. My 20-month-old daughter loves it - can't put a price on that.
Ask me anything about the build, the composite shell, the F-550 platform, weight, insulation, power system, or what I’d do differently.
kidkia@reddit
Is that a bathtub?
mwtownsend@reddit (OP)
it is not. What are you looking at, lol?
Bright-Bluebird-593@reddit
Pic 9, I thought the same and for the little one lol
kidkia@reddit
Thanks I feel less dumb now :)
ScottyMmmmmmm@reddit
Wow
Rolling_Heavy@reddit
How much do you think you spent?
Any issues with condensation in the winter?
How fun is it to say monocoque every time someone ask about it?
mwtownsend@reddit (OP)
Just under $250K including the truck
a little condensation at the very corners and the little domed skylight condenses a little
it's the highlight of my day
poopbucketchallenge@reddit
Someone on r/skoolies was asking $125k for a build they claimed was at $200k.
It looks comical in comparison to yours, especially considering the bus was maybe $5-10k tops to buy new and was the entire structure they built out.
How the fuck did you do this for $250k? Was the 550 used? A crew cab/4wd/6.7 and the super single conversion would be like $100ish new depending on options and if you got a chassis cab
mwtownsend@reddit (OP)
F550s only come as chassis cabs
No-Squirrel6645@reddit
is this the biggest ford f series? I drove an f350 for work and that was a chonker, can't imagine a 550
Dubbinchris@reddit
I used to work in an Ambulance that was based on an F650 crew cab chassis. I think it was $150k just for the chassis. After converting to an ambulance and adding all the equipment it approached $1,000,000. Of course it was a highly specialized mobile intensive care unit for premature babies. We had a few of them.
No-Squirrel6645@reddit
jeez this is like the hippopotamus of ford trucks haha. had no idea they made them this big. thanks for sharing
parkerhalo@reddit
They go up to F750 but I don't think they're physically larger than a 650.
Dubbinchris@reddit
Of course! We split our time between these trucks and an equally equipped helicopter. It was the highlight of my career.
Expert-Rub5947@reddit
Ford makes a f-650 but it doesn’t follow the same body as the f-550. I got a recent quote for a new f-600 utility vehicle which came out to around 200k fully setup but the f-600 follows the same cab design as the f-550
PonyThug@reddit
They make a f750 That way bigger than the f650 the other dude posted.
No-Squirrel6645@reddit
Dude I just want to rent one and mad max that shit in the desert
mwtownsend@reddit (OP)
Indeed; there's always someone with a bigger truck...
mwtownsend@reddit (OP)
It's easy to get upside down on a build like this... Fortunately I didn't have to pay too much for trades - unfortunately that meant doing 90% of it myself. I also have a ton of tools and, for the most part, know how to use them.
poopbucketchallenge@reddit
Where did you make the monocoque? I’d imagine it’d be doable to work on it/paint in a bigger pole barn but making the thing all one piece is nuts.
What did the chassis and SRW conversion cost? I was pricing F450s for a work truck/179 deduction and they had the option for either lol. A loaded platinum with a bed was like $120k but completely gorgeous
mwtownsend@reddit (OP)
Looking at a Ram4500 for the European market; the higher trims are really really nice.
The shell was made by a really high end composite shop overseas that specializes in big assemblies (wind turbines, housings for big medical devices, bus parts, etc.). It comes as two parts and gets bonded together in Denver.
I priced it out a bunch of different ways but anyway you look at it, it made sense to work with the company who was really uniquely positioned to make big vacuum infused parts.
slowracingdriver22@reddit
Would you be willing to share what the shell & subframe cost?
kaloric@reddit
The problem with skoolies is that, no matter what you do with it, it's still a skoolie. I have difficulty seeing anyone paying over $50k for a skoolie build, and it would have to be a turnkey premium build to even be worth that much.
But also, part of the appeal of skoolies is folks building their rigs on the cheap, themselves, starting with a bus they got at auction for less than the price of a 10-year-old Corolla, because they don't have >$100k laying around.
desertSkateRatt@reddit
Okay so I guess I'll ask since nobody else has yet... how do you keep the booze from launching airborne over the first bump? Lol
Also, do you have any specific trips planned? Like PanAmerican highway or Trans America route? Are you coming to Overland Expo West in Flagstaff to let others drool over your rig in person? Haha
foodfighter@reddit
Glad I'm not the only one! The thought of a glass bottle piling down onto that induction cooktop and turning it into an ocean of tiny little bits of tempered glass when you're out in the middle of nowhere...<>
Bright-Bluebird-593@reddit
What's the third bottle of red from the left while we are at it? Dont recognize
Beautiful build man! Congrats on the adventures to come with the fam 🍻
mwtownsend@reddit (OP)
lol, picture 10 - there's a wood bar that holds them on the shelf. It works great!
We're trying to take like 4-6 weeks this summer and travel west through Colorado, Utah, and down through central coast. I'd like to hit some shows but we'll see... I'm more of a one-on-one guy.
bfultonkc@reddit
Sooo curtain rod hooks on each end? Made your own?
VizVizerson@reddit
Where did you get the pet insulation, any more specs on that?
BrWy70@reddit
Please share a YouTube video on your build
Frogboy311@reddit
Soap on the shelf with Pappy! Perfect. Is the Pappy in your build cost?
Endi_ellis@reddit
You can just make a custom composite shell and plop it on a truck? I feel like this is going to turn into me not being able to stop thinking about it now
193686@reddit
This is a beautiful rig, amazing work
ADKTrader1976@reddit
This is what we call posers boys and girls.
p4x4boy@reddit
dude thats a lot of booze. lol. and so many luxury details.
amazing build.
stefanmarais@reddit
Fantastic build.
Rox217@reddit
Your rig is nicer than my house, goddamn. Awesome stuff!
Saw in another comment you might come thru Colorado this summer, I’ll wave if I happen to see you 🤙🏻
mwtownsend@reddit (OP)
Don't feel bad, It's nicer than my house, too.
Rox217@reddit
😂 love it. Safe travels.
Mother_Shopping2856@reddit
This is one of the sickest builds I’ve seen. Reminds me of a Dodge build I walked past in the Denali Park lit that blew my mind. Awesome work!
Wrong_Turn_2232@reddit
That 25-year Pappy is a beauty, bet it hits even better out in the middle of nowhere. Awesome build, by the way. Hope it brings you plenty of great adventures!
highalti@reddit
God Bless you and your family, what a life dream.
cookerspen@reddit
Big Negroni fan?
TrevorSP@reddit
Nice build! I'm diggin' the Artemis and turntable
mwtownsend@reddit (OP)
Don't tell anyone... it's for show. That space turned out to be too valuable as the changing table, lol. That said, I did test it, and it plays really beautifully - no skipping. Props if you know the record in the photo.
Icy-Understanding895@reddit
SS4L
Same_Lack_1775@reddit
You mentioned an overseas manufacturer- what company made the shell?
It looks like you are cutting out the door in one of the photos. Did customs give you a hard time taking delivery of an unopened box?
What was the issue with the custom windows? Were they custom sized or did you not go with off the shelf brands?
mwtownsend@reddit (OP)
Ever Overland made the shell (EverOverland.com)
No issues with customs; we imported in high cube containers. Issue with the custom windows was they were just too time consuming. They work well now but it was months of trial and error.
Same_Lack_1775@reddit
Everoverland appears to be your company. I was referring to which company made the shell. You already indicated “The shell was made by a really high end composite shop overseas that specializes in big assemblies (wind turbines, housings for big medical devices, bus parts, etc.).” What was the composite shop?
Starfield00@reddit
I can't afford anything like that, but I'm very happy on your behalf. That thing looks awesome 😎
fatmaneats17@reddit
Not sure if this one or another one I saw in Encinitas a few times?
Joooooooosh@reddit
This feels hilariously over specced. A big 6.7 F550, like really?
A 6 (metric) ton vehicle for family trips from an outside perspective is just such stereotypical American excess.
Have to respect the “fuck it why not” approach but it’s very obviously a flex that will just get sold once the project is over.
As you can tell, I don’t dig it. Way too OTT but congrats on putting together such a large project.
easynap1000@reddit
I feel its a bit OTT too. We have spent 2 months in our travel trailer- it is by no means perfect but this rig seems to put form over function. One wide open shelf for alcohol? Its got Instagram vibes all over it.
mwtownsend@reddit (OP)
I mean, we’re bipedal monkeys on a floating rock surviving on the kindness of a giant ball of fire a million miles away... this whole thing is a little ott.
I spent a lot of time thinking about this at the beginning of this project. Two thoughts: if you design with intention, it's not harder to make something really interesting and beautiful. 2.) This vehicle is built for my family; it's not a one size fits all.
easynap1000@reddit
Great if it works for you! That may make it harder to sell at 425k if it was built specifically for your family’s needs tho.
lutacool@reddit
Congrats...nicely done, bests for the memories ahead 🙌
FrostyUnion4035@reddit
Kinda gay
overlanding-ModTeam@reddit
Be Kind, Be Respectful
majornerd@reddit
If there is a chance to see it in person, please let me know. This is extremely cool.
mwtownsend@reddit (OP)
Where do you live? Hit me up if you’re ever passing through DFW-
majornerd@reddit
Damn I thought you were in Denver. But I will hit you up when I’m in dfw next.
Illustrious_Egg_1837@reddit
I am envious! Truly envious!
mwtownsend@reddit (OP)
Thank you, friend.
TheTemplarSaint@reddit
Do you know the approach, breakover, and departure angles?
mwtownsend@reddit (OP)
Approach: 30°+ / Departure: 14-22° (depending on the spare tire). As with most vehicles, breakover angle is the primary limitation.
jankyjuke@reddit
Where do you plan to take that thing?
mwtownsend@reddit (OP)
WEST! Planning to go to Utah for paragliding and then head down through northern California through central coast with some vanlife friends. Super pumped.
joshuaherman@reddit
Do you use cad as part your build or did you just kind of wing it?
mwtownsend@reddit (OP)
CAD
kaloric@reddit
Do you have a spare tire carrier somewhere?
It's a nice looking build. I think the monocoque-on-frame looks a lot cleaner than the flatbed removable campers, probably a lower center of gravity and substantially lighter weight than them, too.
mwtownsend@reddit (OP)
Good question: Spare will mount tucked up under the bumper; it takes away a little from the departure angle, but it's not too bad.
I suspect the vertical CG is a little lower and shell weight is likely a little more for a moulded shell vs FRP but that changes when you start working with carbon fiber. The real win for a moulded shell is there are no seams that need maintenance and it's wildly stronger - so when you suck up a tree branch it's not a big deal (ask me how I know...). The strength also shows up in the cabover: it's a lot larger than on the FRP shells I've seen which moves your horizontal CG forward and provides more usable space.
bavmotors1@reddit
did you build the interior out yourself?
GopnickAvenger@reddit
Have I seen this at Sierra at Tahoe?
mwtownsend@reddit (OP)
You probably saw this shell's twin - it's being upfit by the owner of GlamperVans - super super super cool dude.
Even_Echidna6746@reddit
This is an awesome build and something you very much should be proud of.
mwtownsend@reddit (OP)
Thank you.
fishEH-847@reddit
The bottles of booze that will fall on the glass stovetop and the record player are nice touches. 🤪
mwtownsend@reddit (OP)
they haven't yet-
earthlingjim@reddit
Good job!
-from a guy who's had a hand in building~300 or so EarthRoamers.
mwtownsend@reddit (OP)
Thank you, what do you do there?
earthlingjim@reddit
I weld/fab all the aluminum bits. Front/rear bumps, storage boxes... etc. In the early days tho, I/we all wore many hats.
Your fit/finish looks fantastic. That's a lifetime project to be proud of for sure.
mwtownsend@reddit (OP)
Thanks man. Really respect your work as well. Keep up the good work!
blaircook@reddit
The bathroom is giving White Lotus opening credits.
mwtownsend@reddit (OP)
highest compliment I could receive.
planetary_beats@reddit
I’m ignorant when it comes to these big boy diesel engines, how reliable are they overall? Is the 6.7L power stroke something you sought specifically, and if so why? These big diesel trucks fascinate me lol
kaloric@reddit
They're rather reliable and typically last longer.
They make really good low-end torque.
The reason I'd always go with a diesel is that they have excellent engine braking. Gassers have basically nothing and it's rather unpleasant to be braking down steep grades. At best, you're just replacing brakes constantly; at worst, you catch your rig on fire or you have a runaway situation when they overheat & fade.
I happen to live near a couple of the worst interstate descents on I-70, RVs burn down around here with some frequency.
mwtownsend@reddit (OP)
The engine braking is really nice on this truck; you're right. I haven't driven the gas equivalent to see the difference, but that's definitely a consideration.
mwtownsend@reddit (OP)
Honestly... I think they're really reliable but we'll see. It does come with a 100K mile warranty. That said, I'll go gas next time for sure. They're cheaper to buy, cheaper to work on.
Unless you're pulling something big (a big boat or Jeep or something) the gas engine is probably cheaper to drive: lower MPG but no DEF and cheaper gas. That said... I crossed the Raton pass at night and didn't know I was over it until I started to decend. it just cooked up on cruise control at 68mph; no drama.
planetary_beats@reddit
Hey man if you got the money to buy/service em… why not haha. It’s got to feel good driving that thing knowing you literally cannot get stuck anywhere. Enjoy it, I’ll be pissing around in my in-line 4 turbo truck 😂
youthson1c@reddit
Then why was it listed for sale 3 days ago?
https://expeditionmeister.com/expedition-trucks/other-off-road-trucks/2024-ever-overland-ford-f550-demonstrator-the-off-road-off-grid-rolling-vinyl-bar-of-your-dreams-i1919
StopItWithThis@reddit
Looking through his history, it looks like he may actually have built two of them or one is in process?
mwtownsend@reddit (OP)
Another matching shell is being built by another upfitter in Oakland, CA. It’s confusing because we both liked the color (Toyota Lunar Rock) but there are little differences between them.
mwtownsend@reddit (OP)
Lead generation
Sweatycamel@reddit
Wait until you find out about Yachts. They are always for sale for the right price
Chris00008@reddit
I can tell he's a "fake it til you make it" kinda guy. Sold his design company. I mean what exactly is a design company without the designer?
Tongo4President@reddit
Because he wants to make 200k after selling his company
rabid_spidermonkey@reddit
I mean, it's for sale for $425,000. Is it really for sale?
I would also sell for $175,000 profit though. And then make a better one.
Buba_Fatt@reddit
Well, it's listed for almost twice the price that OP said it costed (excluding hours of hard work and experience). I don't plan to sell my car but if someone came to me and will give me two times what it's worth I will sell it too.
Kermit-de-frog1@reddit
Beautiful build ! I’m incredibly impressed. I too watched all of Andrew’s build ……. But I stopped at a much smaller box pop up design I later sold to a wildlands firefighter ( I could never fit comfortably at 6’3”) , and I warned him before he flew in of that issue, Dude didn’t say anything, He shows up at the airport and he’s about 5’4”-5’5” and built like a fireplug . Fit him awesome , and much more comfortable Than their base camps normally are
mwtownsend@reddit (OP)
That's funny. I'm also 6-3 so vanlife was never an option for me.
My daughter's second favorite stuffy is a Kermit the frog, btw.
Kermit-de-frog1@reddit
Awesome! Kermit has been my nickname forever 😎 , And I’m sure your family is going to have a great time in a rig YOU built !
HTH_OTR@reddit
All the places I’d want to take a 4x4 are not going to accommodate this type of behemoth. I don’t get it. There seems to be a narrow window these fit in between typical RV campsites and inaccessible areas that you can hit with a normal 4x4 vehicle. I’d love to hear what I’m missing here so please help me out!
HaYterAyD@reddit
I’m riding with you next time
cincydvp@reddit
Sufjan’s Carrie & Lowell.
usual_suspect_redux@reddit
Nice craftsmanship. Kudos on doing (most of) it yourself.
desertSkateRatt@reddit
Also, just a comment...
Its wild to me to see builds with that significant of overall weight (10,000+ pounds). In a lot of countries you would be required to have an equivalent CDL to even drive something like that on roadways.
Do you have any significant experience driving big rigs, OP?
mwtownsend@reddit (OP)
I drove a moving truck with trailer (for my CNC) from DFW to Portland. This isn't that much different than a regular F-250. The truck chassis was almost 10K lb with super singles... The hab only adds like 5500lb.
thekrakenblue@reddit
this is wild too me my kimbo is like a 5th the weight but it looks dope as fuck man
joshuaherman@reddit
If you were to do it again is there anyway to save weight?
Indentured-peasant@reddit
At 7.5 tons, watch those slippery places
C1ncyN15m0@reddit
This is a mobile home I'd never leave! Great job!
toolgirl77@reddit
I am curious about the tool kit you keep in your vehicle? LastBestTool on youtube talks about building overlanding tool kits a bit on his channel!
jflogerzi@reddit
bro that thing looks nicer then my house on finish and style. Seriously nice job. Are you living in it full time?
KraljZ@reddit
What did something like this cost to build if you don’t mind me asking?
GuaranteeFit9312@reddit
Good for you man! Nice rig, I hope it treats you well.
briggs851@reddit
I like how there’s a bottle of Pappy Van Winkle nestled in there
Most_Talk_2067@reddit
Great job. Time to enjoy.
skyscraperNYC@reddit
Sufjan Stevens! It’s been a minute since I listened to him though but awesome artist. Reminds of a time gone by.
Taco_Nights@reddit
What sort of shade do you have over the bed skylight?
mwtownsend@reddit (OP)
none; I wanted to sleep under the stars. Full moons are sub-optimal but it's all part of it.
TheSquirrelWithin@reddit
It’s a glamper
clauderbaugh@reddit
J/K. This looks friggin amazing! You basically built the largest Earth Roamer for 1/4 of the cost. I would sell a kidney to have the resources and time to do this kind of project.
ThrowRAEv4me@reddit
Congrats man! I’m jealous for sure.
Medieval_Mind@reddit
Absolutely beautiful interior
mwtownsend@reddit (OP)
thank you friend.
CMCdaGoat@reddit
Wow
image-sourcery@reddit
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