HaDeXPEDITION - The Build

The build

Design & Build Story – From Vision to First Expedition

Vision & Requirements Hans started with a blank sheet and one clear goal: a two‑person expedition camper that could leave the tarmac for weeks without outside support, yet still feel inviting and ergonomic inside. The brief translated into four headline requirements:

True 4×4 capability – chassis, drivetrain, tyres and clearances must withstand rock, sand, snow and mud.
Off‑grid autonomy – energy, water and fuel reserves sized for 10‑ to 14‑day remote travel.
Light but strong structure – weight kept well below the chassis GVW for reliability and legal margin.
Comfortable living – an interior that functions like a tiny apartment, not a compromise tent.

Chassis Selection & Preparation

After comparing Mercedes‑Benz Zetros, MAN TGM and Iveco Daily 4×4 platforms, Hans chose an Iveco Daily 4×4 (extended wheelbase, twin‑cab delete) for its favorable payload, global parts availability and low‑range gearing.

Factory options added:*
24‑v winch prep, differential locks front & rear, reinforced springs, 37‑inch all‑terrain tyres.
Fuel tank enlarged to 400 L (including an auxiliary 110 L saddle tank).

The frame was sand‑blasted, epoxy‑primed and fitted with a three‑point torsion‑free subframe to decouple the habitation box from twist on bad tracks.

Habitation Box Engineering

Hans worked with a specialist composite builder to fabricate a single‑piece sandwich shell:

Layer	Material	Purpose
Outer skin	4 mm GRP	Impact‑, UV‑ and salt‑resistant
Core	44 mm closed‑cell XPS	Thermal break (R‑value ≈ 5.2 m²K/W)
Inner skin	2 mm GRP	Easy‑clean, structural

Corner joints were vacuum‑bonded and radiused to eliminate thermal bridges. Result: a rigid, leak‑proof monocoque weighing under 420 kg.

Layout & Ergonomics

Inside, every millimetre was mocked up in plywood before final build:

Forward galley on the kerb side with a 90 cm induction‑diesel dual hob, 130 L compressor fridge/freezer and pull‑out pantry.
Convertible lounge opposite – two aviation‑style seats with five‑point belts double as dinette chairs.
Aft transverse bed (1.55 m × 2.00 m) on a power‑lift frame; drops over the lounge at night, clearing floor space by day.
Wet bath port side mid‑ship with cassette toilet, teak grate and hydrophobic wall panels.

Worktop heights, seat depths and grab‑handle positions follow ISO 14738 ergonomic zones, so movement feels natural even when the truck is pitched.

Energy & Electrical System

Roof solar: 4 × 200 W mono‑crystalline panels (800 W total).
Battery bank: 600 Ah @ 24 V lithium (LiFePO₄) – 14.4 kWh usable.
Inverter/charger: Victron Quattro 5 kVA with 120 A DC‑DC alternator charging while driving.
Backup generator: Whisper‑quiet 2.8 kW diesel set in a ventilated locker.
Smart monitoring: Cerbo GX with remote portal access, displaying SOC, tank levels and temps on a 7‑inch touch screen.

Water, Heating & Climate

Fresh water: 300 L food‑grade polyethylene tank + 3‑stage filtration (5 µm, carbon, UV).
Grey water: 110 L heated tank; black water handled by a 19 L cassette for easy dumping.
Heating & hot water: Diesel air heater (4 kW) + 10 L boiler, both running off vehicle diesel.
Ventilation: Two MaxxFan Deluxe roof vents, plus a roof‑mounted A/C unit for shore‑power use.

Off‑Road Hardware

Integrated 10‑tonne hydraulic winch behind the front bumper.
Snorkel and raised diff breathers for river fords up to 800 mm.
Underride and fuel‑tank guards in 6 mm aluminium.
200 psi onboard air with front & rear quick‑connects and tyre‑inflation kit.
Spare wheel on a swing‑away arm with gas strut assist.

Interior Fit‑Out & Finishes

Cabinet carcasses were CNC‑cut from 10 mm poplar plywood with HPL finish; doors in lightweight honeycomb with soft‑close hinges. Trim theme: graphite grey & warm oak with brushed stainless hardware. All surfaces meet E0 low‑VOC standard. LED strip lighting is zoned (task, ambient, night) and PWM‑dimmed. Cushions use high‑resilience foam, upholstered in marine‑grade fabric with quick‑snap covers for easy washing.

Systems Integration & Testing

Static shakedown: Every onboard system run for 72 h at −5 °C in a chilled hall, then at +40 °C in a heated tent.
Dynamic test: 1 000 km loop through the Ardennes, Vosges and Black Forest – including 14 % gradients and water crossings.
Weight & balance: Final curb weight 5 350 kg, 47 % front / 53 % rear with full tanks, comfortably under the 7 000 kg GVW.

Certification & Handover

The finished truck passed Dutch RDW type approval as an “M1‑special camper” and received German TÜV off‑road exemption plates for oversize tyres. Documentation covers CE markings, gas and electrical certificates, and a comprehensive 150‑page owner’s manual.

Hans christened the prototype HaDeXPEDITION No. 1 and embarked on its maiden voyage: a three‑week winter crossing of Iceland’s F‑roads — a trial by ice, snow and lava that it passed with flying colours.

Outcome

The HaDeXPEDITION 4by4 for2 stands as a testament to Hans’ decades‑long progression from mechanic’s son to master builder. Every step — concept sketch, weld bead, wiring crimp and test kilometre — reflects his resolve to create a vehicle that lets adventurers live comfortably where the map turns blank.

Ready for the next expedition? The blueprint is proven, the workshop is tooled, and production slots are now open for the first customer builds.

HADEX4.com

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