Ford Super Duty Expedition Vehicle
Mission
Our Ford F-250 Powerstroke build stands as a tribute to a vanishing symbol of American resilience—the strong and self-reliant working man. Larger-than-life, loud, and unapologetically excessive, the full-size diesel American pickup is akin to its blue-collar, red-blooded counterpart: once celebrated... but now taxed, regulated, and restricted to near extinction. Modern "emissions standards" have pushed current full-size diesel models into the realm of unreliability, with price tags often exceeding $100,000.
To honor a time when proud American craftsman could still be found, we went back to an era when driving a big diesel truck was more than transportation—it was a badge of honor and a mark of earned success. This project embraces the classic American excess of the full-size truck, reimagined for modern adventures. The result is a large vehicle offering unmatched comfort for extended road trips and considerable cargo capacity, without sacrificing the versatility to tackle some light off-road challenges.
A larger truck means more than just power—it provides more room for tools, equipment, and preparedness. It can be a mobile basecamp with the capacity for stealth camping and sleeping systems that eliminate the need for tents or complex setups. Our mission was clear: to craft a full-size adventure truck that combines comfort, capability, and adaptability, making it equally at home in rural wilderness or urban landscapes.
This build embodies more than just utility; it represents a celebration of independence, craftsmanship, and the enduring spirit of adventure.
Platform
The Ford Super Duty truck is an enduring symbol of American swagger and grit. From the fleets of Texas oilmen to the custom welding rigs that came to represent small business success, the early 2000s Ford Diesel pickups were as iconic as the bald eagle. These vehicles marked the final chapter of Henry Ford's dream to create production vehicles for the common man. While that dream may have faded, its legacy lives on through this build.
At the heart of this project is the Ford 6.0 Powerstroke engine. Known for its impressive power but equally infamous for its mechanical issues, this engine has a complex reputation. However, with proper maintenance and in the absence of factory defects—a frequent challenge for this model—the 6.0 can deliver solid reliability. To overcome its potential flaws, we opted to replace the original engine with a brand-new bulletproofed motor from Ford Racing. This upgraded powerhouse features studded heads and blueprinted components, ensures long-term durability and performance.
The Super Duty's tough and simple design further reinforce its status as a great platform for this build. Solid, heavy-duty axles and full-frame chassis provide the strength and adaptability required for extensive customization. Modifications that can make it exceptionally well-suited for off-road adventures and the demanding requirements of an overland expedition vehicle.
By choosing this 2006 F-250, we’ve not only embraced its heritage but also redefined its potential, creating a platform that’s as resilient and reliable as the American spirit it represents.
Powertrain & Drivetrain
At the heart of this overland expedition build is a brand-new bulletproofed 6.0 Powerstroke engine from Ford Racing. To ensure peak performance and long-term reliability, we’ve added an upgraded aftermarket cooling system, intake, and exhaust. All modern emissions control systems, notorious for making diesel engines unreliable, have been removed. Instead, we’ve opened up the engine with a cold air intake and a big bore exhaust to optimize airflow and allow it to breathe freely.
To address common weaknesses, the underbuilt factory steering box has been replaced with a heavy-duty Red Head steering unit. The fuel pump has been rebuilt with stronger springs to improve fuel delivery, and after tuning the engine to push close to 500 horsepower, the stock transmission couldn’t handle the power and promptly failed. In its place, we installed a stage 3 racing transmission designed to manage the increased output with ease.
The truck’s capability is further enhanced with a 4-inch lift, allowing for larger tire clearance and improved off-road performance. The entire suspension system has been rebuilt with new, upgraded components, ensuring reliability and stability for rugged terrain. This robust combination of powertrain and drivetrain upgrades transforms the F-250 into a powerhouse capable of tackling any adventure.
Defensive Capabilities & Armor
Iron Cross sent us some great bumpers for this build. They look tough and add a considerable level of protection to the truck. Steel bumpers front and back bolted directly to the frame go a long way to protect the truck and passengers while also providing quick attachment points for pulling out stuck vehicles on the trail.
Suspension
We've lifted the truck 4" to provide clearance for larger tires and added high quality Bilstein shocks for increased ride comfort and stability.
Wheels & Tires
We're currently running 20" Fuel alloy wheels and 35" Toyo R/T tires.
Storage
As of right now the storage of this truck is a blank canvas... The bed being capable of modification as desired. Stay tuned to see what we do with storage for the Ford!
Recovery Tools
We've equipped the winch bumper with a 9,000lb winch to start this vehicles recovery capabilities.
Batteries, Electronics, & Off-Road Lighting
Two optima batteries help power the additional amps and subwoofers of our aftermarket sound system BOSS audio has contributed to this build. Auxbeam has set us up with a pretty great aftermarket lighting system we will detail in further updates. For now, check out the YouTube video links below to see the install and testing of the lighting system.
