vehicle construction

As a body and vehicle construction specialist, we deliver extensive conversion and expansion work on your future expedition vehicle - specialized on Mercedes- and MAN-trucks above 7,5 tons. With in-depth specialist knowledge and years of experience in the field of civil, military and municipal vehicle technology, we advise you individually and support you with creativity and expertise.

The subframe - the indispensable link between the vehicle and the living unit


In compliance with the official assembly guidelines of the vehicle manufacturer and in close coordination with the expert vehicle inspectors, we have developed a subframe with no ifs or buts.  


The combined spring- and 4-point diamond-mounted frame unites high driving comfort with robust off-road capability. Our well-proven subframe is suitable both for long distances with its material-stressing continuous strain, as well as for heavy off-road driving with extreme entanglements.


With this enormously important link between the basic vehicle and the living unit, you can rely on the expertise of our body and vehicle construction experts.


Price galvanized from €8,950 excl. VAT.



You can find more interesting insights into the subject of subframes in our related blog post.



Purchase and configuration advice


Choosing a suitable base vehicle is a milestone on the way to becoming an expedition vehicle. We advise on the subject of vehicle selection and configuration as part of our specialization in commercial vehicles from 7.5t from Mercedes and MAN.



Involve us right from the beginning - with experience and expertise, we adapt the vehicle to your living unit requirements and future travel plans in the best possible way, thereby avoiding even complex and costly modification work.



What should be purchased first? The basic vehicle or the living unit? For this consideration, please take a look at our related blog post:



Rear carriers for spare wheels, bikes, motorbike or ATV


REAR CARRIER BASIC Our small load carrier holds up to 450kg and is attached to the chassis of the base vehicle. This means that there is no additional weight on the living unit and subframe, and at the same time driving comfort increases thanks to the lower center of gravity. The lifting winch is operated electrically using a cable remote control. It is suitable for transporting truck spare wheels, but also with an optional extension also for motorcycles or bicycles. Special solutions for your needs and your vehicle are possible.  


Price galvanized and powder-coated in RAL 9005 including mounting from €14,820 excl. VAT.



REAR CARRIER XL The large rear carrier for heavy loads or vehicles with a sloping rear enables a high degree of flexibility thanks to the various interchangeable platforms. Regardless of whether it's an ATV, motorcycle or e-bike, you can always take up to two complete spare wheels with you. The rear carrier is also mounted on the vehicle chassis. The large carrier can hold up to 875kg. If you choose the folding platform or a sloping rear of the cabin, it is designed for a load of up to 675kg.


Price galvanized and powder-coated in RAL 9005 including mounting from €16,280 excl. VAT.



REAR CARRIER M We also offer a rear carrier that is not mounted on the chassis but on the living cabin, for example for the FM2 or other container solutions with twistlock mounts. This carrier is particularly suitable for transporting wheels larger than 14.00 R 20. It carries a maximum payload of 500 kg and can also be expanded to include bicycle or motorbike rails.


Price galvanized and powder-coated in RAL 9005 including mounting from €14,970 excl. VAT.



EXTENSIONS Our rear carriers can be optionally extended with different platforms, custom-made lockable storage boxes, enclosures, sand board holders and bicycle or motorcycle rails. We can also mount additional LED lighting or a reversing camera on the carrier on request.



Ask us, we will gladly advise you! More picture in the galery below.


Fuel Systems & Storage Boxes


FUEL SYSTEMS On request, we can install a larger or an additional tank for your world travel vehicle. In addition, a so-called off-road tank can also be attached, which ensures that there is always fuel at the intake to the engine, even when the vehicle is on an incline. In addition, we offer a tried and tested system for fuel preheating, which protects both the intake and the fuel filter and any AdBlue tank in severe frost.



STORAGE BOXES We manufacture our storage boxes custom-made, so we can also create special shapes. It is suspended from the upper intermediate frame or optionally from the vehicle chassis. The internal storage system in the storage boxes can be adapted to the desired use. The storage boxes are lockable, keyed alike, resilient and are painted in the color of your choice.



Did you know? We also offer a tailor-made outdoor kitchen for our storage boxes with connections for electricity and hot water or a matching storage box staircase.



Ask us, we will gladly advise you!

The first works on the purchased used vehicle


Before the used vehicle can be refurbished, various preparations are necessary, depending on its condition. These include, among others:  


  • the removal of electrical cables that are no longer required up to the driver's cabine
  • the dismantling of hydraulic and pneumatic pipes that are no longer required
  • the dismantling of the old bunk or platform
  • the dismantling of additional power take-offs
  • the disposal of the old structure and any chemical residues

In the next step, we take a closer look at the condition of the exposed chassis, remove further attachments that are no longer required, arrange for rust removal if necessary and give the chassis a new coating or seal.


Frame, wheelbase & axles - on the way to a balanced expedition vehicle


If the desired floor plan has an unfavorable effect on the distribution of the axle loads of the basic vehicle or if an overhang that is too large restricts driving comfort and off-road suitability too much, we carry out a frame extension.  


If axles are in an unfavorable position or if there is one axle too many or too little on the vehicle, we are a reliable partner for a corresponding modification. We prepare existing axle locks for a trip around the world; in individual cases, an axle lock can also be retrofitted.


Our experts for Mercedes and MAN trucks use 3D drawings of your vehicle and the future structure to determine exactly how the change should look like and then coordinate this with you. This includes relocating the air pressure system in the frame or removing other add-on components that are in the way of the new structure. Of course, we strictly adhere to the vehicle manufacturer's installation guidelines in order to be able to carry out a new registration without any problems. After completing the work, we are happy to take care of the necessary tests and the entry in the vehicle documents.


Incidentally, increasing or reducing the wheelbase or relocating a rear axle can also create a significantly more balanced appearance of your expedition vehicle.


Maintenance and repair


Especially for older basic vehicles, we offer the implementation of extensive maintenance and repairs.


Not only are all operating fluids, filters and V-belts replaced, but the brakes, axles and injection are also subjected to an intensive test. Any leaks are detected and eliminated and the vehicle is fully lubricated


Nothing stands in the way of a subsequent presentation to the appraiser.


Let us advise you!


Cabin modifications, crawl throughs & upgrades to the driver´s cabine


CABIN MODIFICATIONS Used basic vehicles from public authorities are often equipped with a large crew cabin or double cabin (DoKa). If you are only traveling as a couple and if you prefer to use the space for a longer cabin, you can shorten the cabin. Of course, an extension or other changes to the vehicle cabin can also be implemented.  



CRAWL-THROUGHS The hatch is an emergency exit, bad weather alternative and, when open, it is also an optical enlargement of the living area. Many customers therefore appreciate this direct connection between vehicle and living cabin. Professionally and always in accordance with the construction guidelines of the respective manufacturer, we provide the crawl-through with a noise absorbing cushion, with a high-quality bellows adapted to the maximum torsion and, on request, with the counterpart on the living room with a lockable door.



UPGRADES TO THE DRIVER´S CABINE Would you like a little more driving comfort? Gladly! With a redesigned vehicle cabin, even longer journeys are a pleasure: better noise insulation, separate air conditioning or auxiliary heating, modern interior trim, high-quality upholstery fabrics, USB interfaces, tablet holders, a monitor for the 360° camera and of course comfortable air-cushioned seats for all occupants are possible.



Contact us!


Beschreibungstitel


Choosing the right staircase depends on many factors - we offer two different solutions that are versatile.



STORAGE BOX STAIRS The extremely sturdy storage box steps can be folded up and stowed away again in just a few simple steps. The locking mechanisms are intuitive and easy to use, the high-quality heavy-duty slides ensure quiet movement. The aluminum steps are slightly ribbed and thus not only increase slip resistance, but also prevent your furry friend from getting their claws caught. Since the stairs do not stand on the ground, they are less susceptible to dirt and also offer insects no easy access to your living cabin.

Both the storage box and the base frame can be powder-coated in the color of your choice. When ordering several storage boxes, the storage box can of course also be designed to be keyed alike.


We will show you how the storage box steps work in this blog post. An electric version of the storage box stair is in development.



STEPLADDER-STEP The space-saving stepladder is pushed into the container frame. It is pulled out to be used and one end placed on the ground, making it very stable and reducing movement when stepping on it. This type of staircase has the advantage of always being levelled and therefore is always easy to walk on. With a higher number of steps, the stairs can be set up flatter - this not only makes it easier for children to get on, but also for pets.



Each stepladder is custom-made and is basically adapted to the respective vehicle or the respective mobile home.

The paintwork - design element and protective cover at the same time


Some want their vehicle to be camouflaged as well as possible, others have an elaborate foiling design in mind and still others value a vehicle with a high recognition value. No matter what you have in mind - we will be happy to advise you!  


With our various partners for painting and foiling, we ensure a high-quality, resistant and durable outer shell. We work with master companies for commercial vehicle painting.

Lighting, camera system, tire pressure control system and winches


LIGHTING What would an expedition vehicle be without highly functional outdoor lighting? We know the demands of long-distance travelers looking for a suitable place to stay overnight, an adventurous journey through an unlit tunnel or maneuvering at night. We upgrade the existing, for example, H4 lighting with more powerful spotlights, retrofit high-quality modern LED headlights and offer the installation of suitable light bars, daytime running lights, side and underbody lighting.  



CAMERA Optionally, high-resolution 360° IR cameras can be integrated into the efficient outdoor lighting. These offer valuable support in maneuvering, overtaking and parking in the driver's cabine. In addition, the camera package offers the possibility of keeping an overview of the surroundings with the integrated wide-angle cameras and an additional monitor from the living area.



TIRE PRESSURE REGULATING SYSTEM A tire pressure regulating system is indispensable for everyone who likes to drive off the beaten track. Whether on the beach in the soft sand, in the forest on muddy tracks or on sodden meadows - with a quickly set reduced tire pressure you can easily cope with situations like this and similar ones. We offer a very simple version with manual pressure setting or a zentralized controlling system.



WINCH Adapted to your vehicle, we will install a high-quality and powerful winch at the front and / or rear. In connection with a redesign of an existing bumper and the use of LED headlights, the mounting for a winch can also be provided at the same time.



We would be happy to advise you individually on further suitable recovery equipment for your vehicle. Or take a look at our revovery equipment shop.


  • vehicle construction allroad expedition truck off-road Mercedes refurbishment subframe basic vehicle rig cabin works wheel base 4x4 4by4 world travel mobile MAN IVECO Blissmobil Krug Steyr Excap

    Rear rack

    individually adapted to 

    what you  want to take with you...

    To the product description
  • Pull-out platform

    subframe with integrated

    balcony platform

    To the product description
  • Subframe

    combined spring and diamond bearings, 

    fully galvanized and painted 

    in the color of your choice


    To the product description
  • Subframe

    3D-constructed, simulated, balanced -

    custom-made for the vehicle and cabin

    To the product description
  • Basic vehicles

    buying advice with expertise

    To the product description
  • Fuel systems

    high-quality workmanship, 

    easy to use and 

    tailored to your travel plans

    To the product description
  • Fuel systems

    filter systems, tank balancing,

    off-road tanks and arctic kit

    To the product description
  • Made-to-measure storage boxes

    adapted to your needs and 

    tailored to your vehicle

    To the product description
  • Chassis preparation

    upgrade for the used base vehicle 

    from the master specialist

    To the product description
  • Frame extensions

    professionally carried out work on the chassis 

    according to customer requirements 

    and detailed advice

    To the product description
  • Engine, chassis & transmission

    engine and fuel consumption optimization,

    chassis adjustments and off-road transmission

    To the product description
  • Illuminated

    functional lighting concepts

    for your expedition vehicle

    To the product description
  • Lighting

    functional and energy-saving

    To the product description
  • Refurbishment of the driver's cabine

    completely renewed and professionally upgraded 

    for the feel-good factor even while driving

    To the product description
  • Crawl through

    including interior 

    adaptations

    To the product description
  • Refurbishment of the driver's cabine

    equipped with air conditioning, radio system, 

    auxiliary heating and much more ...

    To the product description
  • Painting

    high quality industrial paints,

    effects and wrappings

    To the product description
FAS Expedition Expeditionsmobil kaufen Wohncontainer Wohnaufbau modulare Wohnkonzepte Leerkabine selbst ausbauen Selbstausbau Sondercontainer Blissmobil Kerkamm Krug Excap Boxmanufaktur Mercedes Expeditionsmobil Fahrzeugaufbereitung Zwischenrahmen Hilfsrahmen MAN IVECO Steyr Excap Weltreisemobil

Galery Vehicle Construction Works

Are you interested in our services or products? Get our inquiry data sheet, because we can use it to create a personal and, above all, meaningful offer without asking too many questions. Simply download, fill in and use our contact form for uploading. Alternatively, you can of course send an email directly to info@fas-expedition.de .

Download inquiry data sheet
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