A Dodge for Work & Play: Overland Ram 2500

Work hard, play harder.

Many American households still have a full-sized truck that serves as a second vehicle, work truck, and/or weekend outdoor adventure-mobile. While you can just throw your camping and outdoor sports gear into the back of your pickup and go, wouldn’t it be even better if you had a truly capable vehicle, which could not only get you way out there and back again, but also offered all the comforts of home on your adventures? Mario Donovan, owner and lead designer at AT Overland Equipment, has taken this concept to new heights with his Ram 2500 overland adventuremobile build.

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Global Ready

Mario needed a vehicle that could haul and tow large loads for his business, take him to remote locations across the continent, be a comfortable full-featured mobile office and offer all the comforts of home for him and his wife Anne, on their extensive travels.

Besides all those daily uses, he also wanted to demonstrate that it is possible to create a global-ready, yet attainable, American-made full-size 4×4 vehicle that could be competitive with the likes of purpose-built, self-contained European overland vehicles—all for less than 100 grand. Though an extremely lofty goal, Mario managed to pull it off with careful component choices, meticulous attention to detail and impressive execution.

Key Concepts

One of Mario’s key concepts behind this build was for the base vehicle and camper not to be interdependent. This gave Mario the added bonus of flexiblity and the benefit of independent use of the camper and truck. And, if there was an accident or catastrophic mechanical failure that disabled the vehicle, Mario could quickly and easily hook the camper up to another vehicle.

Mario’s Ram 2500 creates a distinct advantage over similar overland, expedition-style van, truck and commercial vehicle builds, where the base vehicle attaches to the living accommodations. Besides protecting your financial assets in the case of failure of either the vehicle or camper systems, this concept also provides the multi-functionality of an adventure-mobile and work truck in a singular vehicle.

A Solid Foundation

The first step in this build was to find an extremely solid foundation, which somehow met all those lofty multi-function design goals. A quarter- or one-ton vehicle satisifes the weight capacity and short wheelbase provides better off-road maneuverability. A Diesel engine provides needed torque for hauling and towing, while also providing fuel efficiency.

In order to be global-ready, the diesel engine needed to be a pre-DEF model, as DEF fluid can be near impossible to find in other parts of the world, and have international parts and service infrastructure availability. Mario surmised that the best American vehicle to meet all these requirements (and be a successful overland rig) was the third generation Dodge Ram regular-cab Cummins diesel 4×4 pickup, specifically, in this case, a 2008 2500 model with the 6.7L Cummins.

In the Workshop

With a solid foundation chosen and acquired, Mario then got to the task of making the base vehicle ready for truly off-the-beaten-path adventures. Wheels, tires and suspension are always the first, and probably most important, step in this process. Solid AEV Katla 17-inch wheels were wrapped with aggressive 37-inch General Grabber tires. This combination allows for low tire pressures, and the best traction possible in a wide variety of terrains.

A four-inch lift provides ground clearance and enough room to stuff those 37s under the truck, while custom valved ICON Stage 3 shocks, at all four corners, smooth out the bumps in the road—or lack thereof. Air bags in the rear help to level the load, and allow full articulation of the rear axle with bottom detatchment. The suspension system is finished off with custom ALCAN rear leaf-spring packs, which are designed to handle the specific loads this vehicle will normally have onboard.

Even with the increased ground clearance, it is important to also protect all the vital systems under the truck, which Mario accomplished with a full complement of custom trail armor. To protect the front of the vehicle in traffic, on the trail and against roadside wildlife, an ARB front bumper was fitted, which provides a secure mounting point for the Comeup 16.5rs winch, and is one of the few airbag-compliant winch bumpers on the market.

Go-Anywhere Package

Fuel range is always important when exploring the backcountry, so a second fuel tank utilizes space in the stock spare-tire location. To have the diversity of power and economy needed from this vehicle, a Banks engine-management unit was fitted, which provides better fuel economy on the highway, as well as more power when needed, in off-road and towing situations. The go-anywhere package on this Ram 2500 overland build was finished off with a completely upgraded steering system, as well as front and rear ARB Air Lockers.

In order to provide the versatility and storage capacity required of this vehicle, a flatbed foundation was the only option to mount in back of the cab. A modified standard Semi Service Truck flatbed provides a secure mounting point for the living quarters while maximizing storage space at the same time. Just behind the truck cab on the flatbed, a large storage box provides a mounting point for the 37-inch spare tire and additional storage for large items. Custom, removable composite under-bed storage boxes provide room for full rear-axle articulation, and maximum storage capacity, while being lightweight, serviceable, and weather resistant.

Working from Home

Now that the vehicle was ready to go anywhere while carrying a load, it was time to mount the mobile office and living space. Mario chose a ’15 Four Wheel Pop-Up Campers Hawk flat-bed model for this project. This decision was an easy one, as the harshest conditions around the globe have proven Four Wheel Campers to be tough.

Its aluminum-frame construction creates an extremely lightweight and durable structure, which can take the beatings that true off-road adventures will dish out, while not diminishing the vehicle’s capabilities with unnecessary weight. The Hawk flat-bed model provides maximum living and storage space available on this vehicle platform, while still providing enough room on the flat bed for the storage box housing the larger than stock spare tire.

2008 Dodge Ram 2500

Platform:

2008 Dodge Ram 2500 Regular Cab Long Bed

Engine:

6.7 Cummins Diesel

Suspension:

ICON Vehicle Dynamics Stage 3 Suspension with Custom Valving (4-inch lift), ALCAN Custom Rear Leaf Spring Packs, Airlift Ride-Rite Air Bags in Daystar Air Bag Cups

Wheels & Tires:

F&R: AEV Katla Wheels 17 inches / General Grabber Tires in 37X12.50R17

Armor:

ARB Deluxe Front Winch Bumper, AT Overland Trail Armor

Accessories:

Semi Service Truck Flatbed, Banks IQ 2.0 Performance Interface, Secondary 42 Gal Fuel Tank (in factory spare tire location), National Luna Dual Battery Management System, AT Oveland Electrical Management System for Lights, Compressor, Lockers & Accessories (with low voltage disconnect), Comup Seal Gen2 16.5rs Winch, ARB Air Lockers and Twin Compressor, ARB Intensity LED Driving & Spot Pattern Aux Lighting, AT Overland Composite Underbed Storage Boxes, AT Overland Composite Tunnel Storage Box (stores 37-inch spare tire & gear), Recovery Equipment: Maxtrax Recovery Boards, Hi-Lift Jack Xtreme & various shackles, snatch blocks, straps, etc., Yaesu 2M Ham Radio, Wilson Electronics Cellular Signal Booster

Camper:

2015 Four Wheel Pop-Up Campers Hawk Flat Bed Model

Camper Upgrades:

Waterless Wrappon Toilet System, 110 Liter Fridge/Freezer, Forced Air Furnace, 160 Watt Solar with 220 Amp Deep Cycle Battery Storage, 26 Gallon Fresh Water Tank, Fiamma F45 2.6 Awning, Custom Entry Ladder

FREQUENTLY ASKED QUESTIONS

What is the Prospector XL and why is it significant?

The Prospector XL is an off-road powerhouse created by American Expedition Vehicles (AEV), known for its formidable capabilities and bold design. AEV is a top player in the aftermarket industry, renowned for producing durable and reliable modifications that exceed standard expectations.

Key Features of the Prospector XL:

Tires: Equipped with massive 40-inch tires, the Prospector XL dwarfs most off-road vehicles. These tires not only enhance its rugged look but also significantly boost its off-road performance.
Suspension: AEV’s DualSport RT Suspension system lifts the vehicle to a height of 84.6 inches. This elevation is about 4.4 inches higher than that of a standard Ram 2500, giving it a commanding presence and superior off-road capability.
Width: Fender flares expand the truck’s width by nearly five inches, making it 88.2 inches wide. This increase provides better stability over rough terrains.
Design: The vehicle’s off-road bumpers are designed to be functional and robust without appearing oversized or gaudy, maintaining a balanced aesthetic.

Why is the Prospector XL Significant?

The significance of the Prospector XL lies in its exceptional blend of power, durability, and style. Unlike other heavy-duty trucks, it offers a unique combination of features that cater to serious off-road and overlanding enthusiasts. Its monumental tire size and elevated suspension system are not just for show; they offer tangible benefits in rugged environments.

Moreover, the Prospector XL addresses a unique market need: it provides an answer to those who seek a heavy-duty truck with the capabilities of a full-scale off-roader. Its design and engineering make it clear why it’s held in high regard in the aftermarket world, offering a level of reliability typically expected only from original manufacturers.

In conclusion, the Prospector XL stands out as a monumental vehicle in the realm of off-roading and overlanding, combining AEV’s expertise with a set of features that make it both a formidable performer and a visually striking machine.

How does the Prospector XL handle off-road conditions?

The Prospector XL showcases impressive off-road capabilities, making it a top contender in rugged terrains. With its substantial 40-inch tires, the vehicle effortlessly conquers large obstacles. For example, it can easily scale and traverse over big concrete blocks, demonstrating its superior traction and stability.

In real-world scenarios, this means that typical obstacles, like downed tree trunks, are reduced to mere speed bumps for this beast of a truck. Its formidable ground clearance and powerful drivetrain enable it to handle rough and uneven ground without breaking a sweat.

The only limitations encountered are psychological rather than physical—the fear of potential damage is the primary concern when pushing the vehicle to extreme limits. But rest assured, the Prospector XL is built to excel in the most challenging off-road environments.

What are the dimensions and modifications of the Prospector XL?

Prospector XL Dimensions and Modifications

Dimensions:

Wheelbase: 149.0 inches
Length: 238.9 inches
Width: 88.2 inches
Height: 84.6 inches
Curb Weight: 8780 pounds

Modifications:

Ram Options:

Level 2 Equipment Group: $4890
Big Horn Package: $4900
Sport Appearance Package: $895
Off-Road Package: $495
Limited-Slip Rear Differential: $445
Bucket Front Seats: $295
Billet Silver Metallic Paint: $200
Auxiliary Switches: $145
220-Amp Alternator: $100
Clearance Lamps: $95

AEV Options:

F1 Leather Upgrade: $3500
Warn TI-S Winch: $2452
Amp Research Power Side Steps: $1571
Full-Size Spare: $816
Vision X Light Bar: $790
Tonneau Cover: $470
Vehicle-Recovery Kit: $435
Rear-Bumper Lighting: $415
Spare-Tire Tie-Down Strap: $275

How does the Prospector XL compare to other heavy-duty trucks in terms of size and practicality?

Size and Weight

The Prospector XL is a behemoth among heavy-duty trucks, with each wheel and tire weighing in at a hefty 141 pounds. This substantial weight contributes to its imposing presence on the road and its rugged appeal. Despite its size, the truck’s acceleration is adequate for everyday driving, keeping it off the list of notably slow vehicles.

Fuel Efficiency

When it comes to fuel efficiency, the Prospector XL averages around 13 miles per gallon. This is on the lower end of the spectrum compared to other heavy-duty trucks, largely due to its weight and robust build. However, this isn’t unusual for vehicles in this category, which frequently prioritize power and durability over fuel economy.

Performance and Modification

While the Prospector XL can hold its own in regular driving conditions, it’s advisable to avoid stoplight drag races. Many competitive trucks, especially those with diesel engines, might have undergone electronic modifications to boost performance. Though owners of the Prospector XL could make similar tweaks for more power, it’s recommended to retain the factory settings. This ensures the engine’s famed reliability remains uncompromised.

Engine and Reliability

The Prospector XL is powered by a 6.7-liter inline-six engine, which is practically industrial-grade. This kind of engine is close to what you would find in commercial semi-trucks, ensuring robust performance and long-term reliability. Tweaking this engine might yield a slight increase in power, but it could also jeopardize the truck’s dependability, a trade-off not worth the risk for most owners.

Practicality

Despite its considerable size, the Prospector XL is surprisingly manageable for everyday use. Its design and engineering strike a balance between off-road capability and on-road comfort. While other heavy-duty trucks might offer similar features, the Prospector XL stands out for its blend of extreme ruggedness and relative ease of use.

Summary

The Prospector XL is a colossal, powerful heavy-duty truck designed for those who need serious off-road capability without sacrificing everyday practicality. While other trucks might offer better fuel efficiency or modified engines, the Prospector XL’s emphasis on reliability and balance makes it a strong contender in its class.

What is the performance and speed of the Prospector XL?

Performance and Speed of the Prospector XL

If you’re seeking blistering acceleration, the Prospector XL may not be your first choice. While it boasts 370 horsepower and 850 pound-feet of torque, its speed isn’t the main attraction. The best it can do is go from zero to 60 mph in 8.3 seconds, making it less speedy compared to rivals like the TRX or Raptor.

However, this truck is not about racing to the finish line. It’s built for power and resilience. Equipped with hefty 40-inch tires and an optional Warn winch, the Prospector XL excels in challenging off-road conditions. Large obstacles, like concrete blocks or fallen trees, are handled with ease, turning them into minor inconveniences rather than barriers.

In essence, the Prospector XL trades speed for capability, shining brightest when the terrain gets tough and the obstacles get bigger.

What are the specifications of the 2020 AEV Prospector XL Diesel Crew Cab 4×4?

Vehicle Overview

Type: Front-engine, rear/4-wheel-drive, 5-passenger, 4-door pickup

Price Breakdown

Base Price: $71,344
As Tested: $94,528

Optional Upgrades:

Ram Options:
- Level 2 Equipment Group: $4890
- Big Horn Package: $4900
- Sport Appearance Package: $895
- Off Road Package: $495
- Limited-slip Rear Differential: $445
- Bucket Front Seats: $295
- Billet Silver Metallic Paint: $200
- Auxiliary Switches: $145
- 220-amp Alternator: $100
- Clearance Lamps: $95
AEV Options:
- F1 Leather Upgrade: $3500
- Warn TI-s Winch: $2452
- Amp Research Power Side Steps: $1571
- Full-size Spare Tire: $816
- Vision X Light Bar: $790
- Tonneau Cover: $470
- Vehicle-recovery Kit: $435
- Rear-bumper Lighting: $415
- Spare-tire Tie-down Strap: $275

Engine Specifications

Type: Turbocharged and intercooled pushrod 24-valve diesel inline-6
Material: Iron block and head
Displacement: 408 in³ (6690 cm³)
Power: 370 hp @ 2800 rpm
Torque: 850 lb-ft @ 1152 rpm

Transmission

Type: 6-speed automatic

Chassis and Suspension

Suspension (Front/Rear): Live axle/live axle
Brakes (Front/Rear): 14.2-inch vented disc / 14.1-inch vented disc
Tires: Toyo Open Country M/T, 40×13.5R-17LT 121Q M+S

Dimensions

Wheelbase: 149.0 inches
Length: 238.9 inches
Width: 88.2 inches
Height: 84.6 inches
Passenger Volume: 125 cubic feet
Curb Weight: 8780 pounds

Performance Metrics

0-60 mph: 8.3 seconds
1/4 Mile: 16.6 seconds @ 84 mph
0-100 mph: 26.2 seconds
Top Speed (Governed): 101 mph
Braking (70-0 mph): 202 feet

Note: Testing results omit a 1-foot rollout of 0.4 seconds.

Rolling and Gear Acceleration

Rolling Start (5–60 mph): 9.0 seconds
Top Gear (30–50 mph): 4.9 seconds
Top Gear (50–70 mph): 6.8 seconds

Fuel Economy

Observed: 13 mpg
Highway (75 mph): 15 mpg
Highway Range: 460 miles

What additional features and options are available for the Prospector XL package?

Additional Features and Options for the Prospector XL Package

The Prospector XL package comes with several noteworthy features to enhance your driving experience. Initially priced at $19,999, but now available for $20,999, this package is designed to offer both utility and luxury. Here’s what you can expect:

Standard Inclusions

Full-Size Spare Tire: Always be prepared with a full-size spare tire included to handle any roadside emergencies.
Additional Lights: Extra lighting at both the front and rear to improve visibility and safety during night drives or off-road adventures.

Optional Upgrades

Power Running Boards: Convenient and stylish, these boards automatically extend and retract for easier entry and exit.
Leather Seats: A luxurious touch that also offers a practical benefit. Opting for aftermarket leather seats allows you to upgrade a lower-spec model while keeping the overall cost competitive. This means you don’t need to purchase higher trim levels just to get leather upholstery.

By customizing your Prospector XL package with these additional features and options, you can create a vehicle that perfectly suits your needs and preferences, whether you’re prioritizing luxury, functionality, or both.

What are the observed fuel economy and highway range of the Prospector XL?

Prospector XL Fuel Economy and Highway Range

Observed Fuel Economy

City Driving: 13 miles per gallon (mpg)

Highway Fuel Economy

At 75 mph: 15 miles per gallon (mpg)

Highway Range

Total Distance: Up to 460 miles

With these stats, the Prospector XL demonstrates solid performance both in urban conditions and on the open road. The highway range makes it a reliable choice for long journeys without frequent refueling stops.

What are the pros and cons of the Prospector XL?

Pros and Cons of the Prospector XL

Pros

Value for Money: The Prospector XL is priced competitively, especially considering the extensive features and equipment included. You get a lot of bang for your buck.
Unique Presence: It’s a rare vehicle to spot, ensuring you stand out on the road. If exclusivity is your thing, the Prospector XL delivers.
Off-Road Capability: Designed for rugged landscapes, this vehicle excels in off-road scenarios. It’s built to handle tough terrains with ease.
Smooth Ride Quality: Despite its robust build, the Prospector XL offers a surprisingly smooth and comfortable ride, making long journeys more enjoyable.

Cons

Accessibility Challenges: Getting in and out of the Prospector XL can feel like a workout, thanks to its high step-in height. It’s not the best for those who prefer easy access.
Speed Concerns: The vehicle is not the fastest on the market, so if you’re looking for something with quick acceleration, you’d need to look elsewhere.
Parking Limitations: Due to its size, parking can be a challenge. Many parking garages are simply off-limits, so finding a suitable spot can often be difficult.

What is the fuel economy of the Prospector XL?

Fuel Economy of the Prospector XL

The Prospector XL delivers an impressive fuel economy, exceeding initial expectations. Despite its massive tires, increased frontal area, and nearly 9,000-pound curb weight, this heavy-duty vehicle manages better fuel efficiency than anticipated.

Key Fuel Economy Stats:

City Driving: Around 13 miles per gallon (mpg).
Highway Driving: Achieves an average of 15 mpg at a steady speed of 75 mph.

Comparatively, many off-road vehicles in its weight class struggle to break into double-digit fuel consumption, often hovering around 10 mpg. The Prospector XL’s robust performance in fuel efficiency makes it a standout in its category.

How does the Prospector XL compare to Ford’s F-150 and Bronco Raptors in terms of tire size?

When examining tire size, the Prospector XL stands out distinctly. While Ford’s F-150 and Bronco Raptors feature 37-inch tires, the Prospector XL is equipped with substantially larger 40-inch tires. This difference not only sets the Prospector XL apart but also suggests enhanced off-road capability and a more commanding presence on the road.

How does the Prospector XL perform in terms of ride quality and noise levels?

Once you climb into the elevated driver’s seat of the Prospector XL, you’ll appreciate the excellent visibility it offers. However, note that smaller vehicles like Miatas and hatchbacks may blend into its large shadow, so extra caution is necessary.

Ride Quality

Settle in, and you’ll find the ride quality is quite commendable. Thanks to its four massive tires that cushion the vehicle’s body and cabin from the road, the Prospector XL manages to provide a comfortable drive. The suspension does a remarkable job of absorbing bumps and rough terrain, making it a sturdy and smooth performer whether on city streets or off-road adventures.

Noise Levels

When cruising at 70 mph, the interior noise measures 68 decibels. This is surprisingly good, especially when considering the vehicle’s substantial 40-inch Toyo tires, which feature large tread blocks. For context, this level of interior noise is just a bit louder than the 2020 Ram 2500 Laramie, which is only 2 decibels quieter due to its more street-oriented tires.

In summary, the Prospector XL excels in providing a comfortable ride and maintains a reasonable noise level, even with its aggressive off-road tires.

How does the pricing of the Prospector XL compare to other vehicles?

When examining the cost of the Prospector XL, it stands out as an intriguing value in the truck market. Priced at $94,528, this includes the $19,999 Prospector XL package (which has since increased to $20,999). Additional options like a full-size spare tire, extra front and rear lights, power running boards, and leather seats are also part of the package.

Leather Seats Upgrade

The inclusion of leather seats might seem like an unusual choice for a heavy-duty truck, but it actually provides a financial advantage. Standard models require stepping up several trims to access leather upholstery. However, by opting for an aftermarket leather option, buyers can begin with a lower-spec model, ultimately keeping costs competitive.

Comparison to Similar Models

Let’s put this into perspective:

Long-term Ram 1500 TRX: The final cost of the Prospector XL remains within a few thousand dollars of this popular model, offering better exclusivity and a cooler factor.
Other Heavy-Duty Trucks: Many heavy-duty trucks, when similarly equipped, can easily surpass the $100,000 mark. In this context, the Prospector XL offers a more budget-friendly yet equally capable alternative.

Key Takeaways

Value Proposition: Despite its hefty 8780-pound frame, the Prospector XL provides a compelling financial package.
Customization: The aftermarket leather option allows for cost savings by starting with a lower-spec model.
Market Position: It maintains a competitive edge against other expensive heavy-duty trucks, all while providing unique features that make it stand out.

In summary, the Prospector XL offers a balanced blend of value, customization options, and exclusivity, making it a noteworthy contender in its market segment.

Why doesn’t Ram build a Power Wagon with the Cummins turbo-diesel engine?

When it comes to off-road capabilities, the Power Wagon is a beast designed for rugged terrains and challenging activities. However, Ram has opted not to equip this model with the Cummins turbo-diesel engine.

Weight Considerations

One of the primary reasons for this decision is the weight of the Cummins engine. The turbo-diesel variant is significantly heavier than its gasoline counterparts. In a vehicle designed for off-road agility, extra weight can be a significant drawback. The added heft can impact the handling, suspension, and overall performance in off-road conditions, making the vehicle less nimble and more cumbersome to maneuver.

Performance and Balance

Off-road vehicles like the Power Wagon benefit from an optimal balance of power and weight. While the Cumminsturbo-diesel engine provides immense torque, which is excellent for towing and hauling, its weight compromises the vehicle’s ability to tackle steep inclines, rocky paths, and uneven terrains. A gasoline engine, on the other hand, offers a better weight-to-power ratio more suited to the Power Wagon’s off-road focused design.

Engine Bay Space

Engine bay dimensions also play a crucial role in this decision. The Cummins turbo-diesel engine requires more space, which could lead to modifications in the vehicle’s structure or layout. Such changes might not only increase production costs but also impact the vehicle’s off-road geometry, including crucial aspects like approach, departure, and breakover angles.

Customer Needs and Market Demand

Ram has likely evaluated the needs of their target market. Off-road enthusiasts typically prioritize maneuverability and durability over sheer towing power. The current gasoline engine meets these needs more effectively, providing a balanced blend of power, weight, and flexibility.

Alternatives

For those who are adamant about having a Cummins turbo-diesel engine in an off-road capable truck, there are aftermarket modifications and third-party tuners like AEV (American Expedition Vehicles) that offer such conversions. However, these modifications often come with their own sets of trade-offs and additional costs.

By considering these various factors, Ram has determined that a gasoline engine is the best fit for the Power Wagon’s intended off-road use. This careful consideration ensures that the vehicle remains highly capable and reliable in the demanding conditions it is designed for.

What kinds of vehicles does AEV build and sell upgrades for?

American Expedition Vehicles (AEV) specializes in creating and enhancing a variety of off-road and overlanding vehicles. Known for its top-notch durability and reliability, AEV offers upgrades mainly for Jeep models and heavy-duty Ram pickups. Their portfolio also includes collaboration projects, such as enhancing mid-size trucks like the Colorado ZR2 Bison.

Vehicle Types AEV Focuses On:

Jeeps: Comprehensive upgrades for enhanced off-road capabilities.
Heavy-Duty Ram Pickups: Advanced modifications for powerful performance.
Mid-Size Trucks: Special editions with rugged improvements for versatile use.

What is the reputation of American Expedition Vehicles (AEV) in the aftermarket world?

The Reputation of American Expedition Vehicles (AEV) in the Aftermarket World

American Expedition Vehicles (AEV) is highly esteemed in the aftermarket industry, particularly for their expertise in crafting off-road and overlanding vehicles. Renowned for their durability and reliability, AEV’s builds often rival the quality of original equipment manufacturers (OEMs)—a distinction that sets them apart in a competitive market. This reputation is not easily earned; it reflects AEV’s commitment to meticulous engineering and top-notch craftsmanship, ensuring that their vehicles can withstand the toughest conditions. In essence, AEV is trusted for delivering performance and dependability that enthusiasts and professionals alike can rely on.