AEV Ram 2500 Prospector XL Overland Build

When carrying multiple people and related gear into the dirt, a larger platform can make many aspects of the journey easier. Increased payload, more towing capacity, more seats, and a greater range are only a few of the benefits a full-size platform has over something smaller. The AEV Prospector XL can be purchased as a turnkey answer to your big adventure truck dreams, but AEV also sells the components you need to build your own.

Using AEV's HighMark Fender Flares and the AEV DualSport suspension system, it's possible for your Ram to turn 40-inch tires without an issue, in the hinterlands or the highway. Adding AEV's armor package, wheels, and other off-road-centric add-ons contributes to the form and function of the Ram. With a list of parts chosen and the Ram in the service bay, we began the journey to making 40s look like they were there from the factory.

Fitting big tires with minimal lift is the goal of the AEV HighMark Fender Flares, and the company includes detailed instructions for where to cut the wheelwells of your Ram.

After following the procedures, we'll remind anyone considering this project that you will be cutting over three inches of metal from the wheelwells, and it must be done with care. The metal is often double-layered. Take your time.

Using a pneumatic cutter, and a grinder when necessary, we carefully followed the lines.

AEV went to great lengths to ensure that this procedure produces a clean fit, and with careful wheel and tire choice, there should be no clearance issues even at full lock/stuff.

The flares bolt from the inside producing a clean and straight-from-the-factory look. Notice the factory bumper indicating how much material was removed from the wheelwells.

AEV's DualSport suspension system includes Bilstein 5100 monotube shocks, valved specifically for the Ram, and three-inch coils.

AEV's kit includes provisions for moving the front axle 1.6 inches forward to make space for 40-inch tires as well as driveshaft spacers.

Like the front, three-inch-lift coils and Bilstein 5100 monotube shocks are used to maintain a factory-like ride on the HD Ram with its larger rubbers.

AEV differential covers were installed on both the front and rear of the Ram. The AEV covers feature oversized fill ports for easier inspection and filling.

Mounting the Warn 16.5ti-S winch within the AEV front bumper is no small task—both these components are extremely hefty items and the bumper is essentially assembled around the winch. The result, however, is a hard-to-beat frontend protection and extraction package that blends smoothly with the lines of the Prospector XL.

Not that this incredible truck will ever find itself stuck, but if it happens upon a vehicle needing help, AEV offers stout frame-mounted recovery points to affix extraction gear.

AEV 7000 Series LED lights and LEDs from Baja Designs were added to the bumper and to the A-pillars of the PXL build.

AEV Katla wheels sized 17x10 inches were mated with 40x13.50R17LT Toyo Open Country M/T tires, and the combo looks sharp on the PXL. Plus, no rubbing even with these considerable meats.

Adding the full-size spare tire carrier to the bed of the Prospector XL finished the project. The bed area can be easily configured to support a cargo rack, for towing, and for various on- and off-road duties.

The Ram 2500 Prospector XL is a pleasure to drive. On the road, it's like piloting a barge because people move out of your way. However, handling is said to be quite pleasant considering the tires beneath the rig. Warranties remain intact and components like the front bumper were crash-tested. We report 15-18 mpg from our Cummins powerplant, and after more than 30,000 miles, all we can complain about is not being able to fit into the lowest-clearance parking garages.

Follow along as we drive the AEV Prospector XL and the AEV Colorado ZR2 Bison through a challenging off-road course.