2004 Ford F-550 Expedition Rig

$179,000

Make

Ford

Engine

Bulletproofed 6.0L Powerstroke

Model

F-550

Drivetrain

4×4

Odometer

128,500

Transmission

automatic

VIN / Chassis #

-

Location

Durango, CO

Title Status

clean

Seller

private party

Fuel Type

diesel
Built for true off-grid adventure, this 2004 Ford F-550 Expedition Vehicle is a professional-grade, overland-ready rig that rivals the craftsmanship and comfort of an EarthRoamer at a fraction of the cost. Currently located in Durango, Colorado, this one-of-a-kind build was completed over two years with over $190,000 invested in fabrication, systems, and bulletproofing. With 128,500 miles on the chassis and a fully updated 6.0L Powerstroke Diesel, this F-550 is purpose-built to take you deep into the wilderness—and keep you there in comfort. It can be yours for an asking price of $179,000.
  • Purpose-built for overland exploration: The Ford F-550 Super Duty chassis provides an ideal platform for an expedition build—offering immense strength, payload, and durability. This rig has been reimagined from the ground up to deliver serious off-road capability, long-range travel capacity, and true residential comfort for full-time or long-term adventure.
  • Bulletproof 6.0L Powerstroke Diesel powertrain: Under the hood lies the proven 6.0L Powerstroke Diesel, completely bulletproofed for durability and peace of mind. The build includes ARP head studs, upgraded oil and EGR coolers, fresh gaskets and seals, and recent service including an oil change and coolant flush. The result is a dependable, torque-rich engine ready for thousands of miles of rugged, off-grid travel.
  • Rugged, functional exterior design: Finished in a durable, bedliner-style coating, this F-550 is armored against the elements. Highlights include a Buckstop single rear wheel conversion, Buckstop bumper and fender flares, Warn 16.5k lb winch, and massive 42” Continental MPT 81 tires. Full Baja Designs exterior lighting, a rear-view camera, and Starlink-ready cabling ensure readiness for any expedition environment.
  • Luxury camper interior with thoughtful amenities: Inside, craftsmanship meets comfort. A queen-size Tempur-Pedic bed with Froli system, Dometic kitchen appliances, wet bath with glass shower, sycamore countertops, and custom cabinetry make this a functional home on wheels. A dedicated workspace with 4K monitor and Sony sound bar, efficient climate control, and three-zone dimmable lighting support both adventure and remote work in style.
  • Proven and meticulously maintained: With 3,000 miles added since completion, this rig has been thoroughly tested across Utah, Colorado, Idaho, and New Mexico. It remains in excellent condition with recent maintenance completed, including oil service, coolant flush, and inspection. Minor notes include brakes at approximately 30% life remaining and a cab-to-camper separator pad that could be reinforced for rougher terrain.
Vehicle Overview
  • Make/Model: 2004 Ford F550
  • Mileage: 128,500 miles/10MPG
  • Engine: Bulletproofed 6.0L Powerstroke Diesel – fully updated for durability and reliability (details below)
  • Drivetrain: 4x4
  • Dimensions: 25' L x 8' W x 12.5' H (approximate)
  • Interior Headroom: 6'10" tall, 15'8" long, 7'4" wide (approximate)
  • Weight: 15,000 lbs
  • Finish: Recently refinished with a bedliner-style paint for enhanced durability and aesthetic
  • Location: Durango, Colorado
  • Insurance: Easy to insure as an RV; registered as a residential vehicle, not commercial, for simpler insurance and registration.
Exterior Features
  • Single Rear Wheel Conversion: Buckstop, with 42” Continental MPT 81 tires (full-size spare included)
  • Lighting: Baja Design exterior lights all around for optimal visibility, with outside area/work lighting
  • Bumper & Fender Flares: Buckstop Bumper and Fender Flares
  • Winch: 16.5k lb Warn Winch for heavy-duty recovery
  • Backup Camera: Full-time rear camera for easy maneuvering
  • Starlink-Ready: Equipped with a roof space and chase for cable runs, ready for Starlink setup-
Camper Interior & Amenities
  • Water Storage: 72-gallon fresh water tank for extended off-grid stays
  • Wet Bath: Custom glass door shower and cassette toilet for convenience, plus an outdoor shower with hot water
  • Sleeping & Seating: Queen-size Tempur-Pedic mattress with Froli Bed system, dinette seats 4 comfortably (up to 6 seated)
  • Closet Space: His and her closets with ample storage for extended travel
  • Kitchen: Dometic stainless steel 3-burner stove with oven, large Dometic 3-way fridge/freezer, sycamore slab countertops, large under-mounted sink
  • Workspace: Full desk with 4K monitor for remote work or adventure planning, including a Sony sound bar for an immersive audio experience
  • Heating & Cooling: Dometic propane furnace, AC unit, and 2 roof vent fans with intake and output multi-speed settings
  • Lighting & Design: Custom cabinetry, Shu Sugi Ban ceiling, 3-zone lighting with dimmers, ample food and clothes storage
  • Storage: Underfloor and underbelly storage boxes, rear storage boxes, Yakima Skybox, plus 2 1UP bike racks
Power & Off-Grid Capability
  • Solar Power: 525 watts from 3x 175-watt panels
  • Battery Storage: 4x 100Ah Lithium-Ion batteries
  • Inverter: 3000-watt inverter for reliable AC power
  • Propane: 2x 20lb propane tanks for stove, oven, and hot water heater
  • Generator Compatibility: Rear storage box fitted for Honda 3000 generator (not included)
Onboard Storage Capacity
This design maximizes usable cubic footage to carry everything you need:
  • Underbelly and rear boxes
  • Ideal for 2x iSUPs, 2x snowboards, 2x skis, 1x kiteboard, 2x surfboards, 2x mountain bikes, climbing gear, free diving equipment, camping gear, dirt bike, paraglider, speed wing, dog accessories, and much more!
Bulletproofing & Maintenance
To ensure longevity and performance, this rig includes comprehensive upgrades:
  • Head Gasket Kit
  • ARP Head Studs
  • Updated Oil Cooler- replaced 5/25 to be safe as temp increase
  • Heads Checked & Cleaned
  • Rocker Box Gasket
  • Injector O-Ring
  • EGR Cooler- replaced with Bulletproof branded part when replacing oil cooler 5/25
  • Updated Cover Gasket
  • 6.0L Coolant Reservoir
  • Turbo Service (Exhaust Side)
  • Updated STC Fitting
  • Oil Change with Filters- 5/25
  • HDEL Antifreeze- flushed and new as one coolant line had a questionable dry crack 5/25
  • Ford Banjo Bolts
  • Stand Pipes
  • Coolant Filter
  • Blue Spring Kit
Flaws & Imperfections
  • The front and rear brakes will need replacing soon as they are about 30%.
  • The separator pad between the cab and the camper could use some improvement as it bounces out on rough roads.
Designed for serious overlanders and off-grid explorers, this 2004 Ford F-550 offers EarthRoamer-level craftsmanship and engineering for a fraction of the investment. It combines a bulletproof diesel drivetrain, an expertly executed camper interior, and full solar, water, and power systems for complete independence. Whether you’re planning a multi-state expedition or an overland journey from Alaska to Argentina, this F-550 is ready for the challenge.

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