How Much Does It Really Cost to Build an Expedition Truck?
The cost of a full-size expedition truck is often misunderstood because major expenses are bundled, hidden, or assumed away. The clearest way to understand the real cost is to separate the build into four parts:
The truck
The structural shell
Interior systems and materials
Labor (whether paid or owner-supplied)
The estimates below reflect a shell-based, mid-range expedition truck build using realistic components and conservative assumptions—not a stripped-down budget build and not a full turnkey showpiece.
1. Acquiring the Truck (Including Super Singles)
Estimated Cost: $95,000 – $115,000
A common foundation for a full-size expedition vehicle is a 2017+ Ford F-550, selected for payload capacity, durability, and nationwide serviceability.
A stock F-550 is delivered with dual rear wheels (duallies). For expedition use, most builds convert to Super Singles to improve off-road capability and tire availability.
Typical truck-related costs include:
Truck chassis (new or lightly used)
Super Single wheel and tire conversion
Rear fender or flare modifications
Track-width alignment
Speedometer recalibration
Minor suspension or clearance work (not a full aftermarket suspension)
The Ever Expedition Shell is compatible with this platform without requiring aftermarket suspension modifications.
2. Expedition Shell
Ever Expedition Shell: $75,000
The shell is the structural core of the vehicle and replaces traditional framed camper construction.
Included in this price:
Vacuum-infused composite monocoque shell
Four-point hybrid subframe
Integrated storage hatches and floor access
Insulated entry door and cabover skylight
Mounting to the customer’s vehicle
This is a complete, mounted structural habitat, not a kit or unfinished enclosure.
3. Interior & System Materials (Excluding Labor)
Estimated Cost: $60,000 – $65,000
These costs reflect materials and major systems only. Installation labor is addressed separately.
Interior Cost Breakdown
Windows & Roof Openings — $7,000 – $9,000
Expedition-grade windows (e.g., Arctic Tern / Tern Overland) with integrated blinds and bug screens, plus roof hatch or skylight. Includes cutting, sealing, and finishing openings.
Framing & Structural Supports — $3,000 – $4,500
Interior substructures for cabinetry, beds, partitions, and secure mounting of systems.
Insulation (Interior-Applied) — $2,500 – $3,500
Selective closed-cell spray foam or alternative insulation applied during the interior build for air sealing, sound control, and thermal moderation.
Plumbing Systems — $5,000 – $6,500
Fresh and grey water tanks, pumps, plumbing runs, fixtures, and basic water heating.
Heating & Cooling — $5,000 – $7,000
Diesel heater, ventilation fans, ducting, and climate controls appropriate for multi-season travel.
Electrical Systems (Professional-Grade Components) — $14,000 – $18,000
A serious expedition power system typically includes:
10–15 kWh lithium battery bank
3000W inverter/charger
DC-DC charging
Solar charge controllers
800W+ solar array and mounting
High-strand marine cabling, busbars, fusing, disconnects
System monitoring and displays
This reflects parts only, not installation labor.
Walls & Ceilings — $3,000 – $4,000
Interior panels, access hatches, and functional finish surfaces.
Cabinetry — $6,500 – $8,500
Utility-to-mid-grade cabinetry, storage, galley components, and bed platforms.
Appliances — $4,500 – $6,000
Refrigeration, cooktop, water heater, and essential onboard appliances.
Miscellaneous Components — $2,500 – $3,500
Lighting, hardware, fasteners, controls, and the unavoidable small items that complete a build.
4. Labor (Builder or Owner-Supplied)
Estimated Value: $40,000 – $60,000
Labor is a real cost—even when the owner performs the work.
A full interior could require as little as 300 hours of skilled labor or as many as 800 hours. At professional shop rates of $150–$200/hour, a fully turnkey interior would represent $50,000-100,000 in labor alone.
The $40k–$60k figure assumes a hybrid model, where:
The owner performs a significant portion of the work, effectively “paying themselves,” or
A builder provides partial services rather than a full turnkey build
This is not a concourse-level shop build. It reflects a practical, expedition-focused finish where labor is either reduced, phased, or captured as owner value.
5. Total Build Cost (Shell-Based Example)
| Category | Estimated Cost |
|---|---|
| Truck + Super Singles | ~$105,000 |
| Expedition Shell | $75,000 |
| Interior & System Materials | ~$62,000 |
| Labor (Builder or Owner Value) | ~$50,000 |
| Total Build Cost | ~$275,000 |
6. How This Compares to Finished Expedition Trucks
Comparable finished expedition trucks of similar size, capability, and aesthetic commonly retail for:
$375,000 – $500,000+
Shell-based builds often cost less because they:
Avoid paying for predefined layouts that don’t fit the owner’s use case
Reduce rework and customization premiums
Allow labor to be phased or owner-supplied
The result is frequently six figures in savings, without sacrificing capability.
A full-size expedition truck is a serious investment—but the costs are predictable when broken into structure, systems, and labor.
Shell-based builds offer:
Cost transparency
Design control
Flexibility in timeline and labor
Real opportunities to capture value rather than spend it
Understanding these tradeoffs early leads to better decisions—and better vehicles.
