A growing number of overland vehicle builders are offering camper shells as blank slates, sold without interiors. This approach gives buyers the freedom to design and outfit the space to match their own needs. For those with the right skills—or even those willing to learn—it opens the possibility of building the interior themselves, saving money on travel costs while tailoring every detail to their preferences. One example of this trend is the Torsus Praetorian, which we highlighted earlier this year. Designed mainly for the European market, the Torsus follows the same philosophy of providing a rugged platform that owners can adapt to their specific needs.
Now Ever Overland has unveiled their latest offering, the Ever Expedition Shell—a fully assembled composite shell and subframe system built specifically for the Ford F-550, aimed at professionals and serious do-it-yourself builders in the overland vehicle space. In contrast to traditional DIY kits, which often involve multiple pieces, seam assembly, and gluing, Ever Overland’s approach delivers a monocoque-style structure, designed for structural integrity and ease of installation.
The Ever Expedition Shell is constructed as a single, seamless habitat shell that mounts to a custom, high-strength steel subframe. The company emphasizes that this construction method eliminates common drawbacks in conventional builds, such as thermal bridging and panel misalignment during curing or assembly. This comprehensive assembly is completed offsite; Ever Overland either mounts the shell directly onto the customer’s truck or ships it to a designated upfitter, fully assembled and ready for customization.
Structurally, the shell and subframe combination presents a robust foundation. The habitat is bonded to a bespoke, finite element analysis (FEA) tested steel subframe. This integration ensures a durable and reliable base capable of withstanding rugged use and terrain demands.
Natural light and visibility are prioritized in the design. Ever Overland includes a sizeable 9-square-foot tempered glass skylight as a standard feature. In daylight, this element fills the interior with light; at night, it provides a panoramic view of the sky, enhancing the connection to the outdoor environment.
The shell is explicitly tailored for the widely used Ford SuperDuty chassis, targeting model years 2017 and up with the 84-inch cab-to-axle configuration. While compatible with dual-wheel setups, the company recommends converting to super singles to enhance off-road capability and handling.
A detailed set of specifications further frames the product’s form factor and performance. Mounted on the truck, the habitat stands at 11 feet 2 inches in height and spans 21 feet 2 inches in length, including the cab-over section. Its maximum width is 94 inches at the wheel wells, and it offers a maximum inside standing height of 7 feet. The composite shell alone weighs approximately 2,100 pounds (950 kilograms), and the hybrid steel subframe accounts for about 600 pounds (275 kilograms), bringing the combined weight to around 2,700 pounds.
Thermal performance is addressed through structural foam insulation built into the shell, providing an approximate R-value of 6. The company notes that further interior insulation can be added depending on the user’s climate needs and application. The wall thickness is specified as 1 3/8 inches, and the floor thickness is 2 inches.
Ever Overland positions the Ever Expedition Shell as a Stage 1 solution—a blank canvas that includes key exterior elements while leaving interior customization open to the owner. The package consists of a 75-inch by 24-inch Euro-style entry door featuring a multi-point locking mechanism, integrated sunshade, and screen, in addition to the previously described skylight and subframe. Ever Overland does not provide interior furnishings; however, they do offer to connect customers with qualified upfitters to complete the build according to personal preferences and specifications.
In terms of timeline, Ever Overland typically takes about two months to complete the final assembly of each shell. That said, there may be inventory available at various times throughout the year. Prospective buyers are encouraged to reach out directly to confirm current availability and pricing of the shell.
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