Meet the 2025 ‘Ultimate Build’: Overland Expo’s Most Ambitious Rig Yet

May 1, 2025

The GMC Sierra HD AT4X AEV Edition and OEV Back Country Camper form a rugged, no-compromise rig worthy of the ‘Ultimate Build’ title.

FLAGSTAFF, Ariz. (May 1, 2025) /OUTDOOR SPORTSWIRE/ — Now in its fifth year, Overland Expo’s renowned Ultimate Build program continues its tradition of transforming capable factory vehicles into elite overland rigs. For 2025, the spotlight is on the all-new GMC Sierra 2500 HD AT4X AEV Edition, a powerhouse that seamlessly blends rugged off-road capability, advanced technology, and premium comfort. This formidable platform is paired with the OEV Back Country Camper, a slide-in truck camper, resulting in the ultimate overland adventure vehicle.

Engineered for overland travelers who demand uncompromising capability and reliability, the 2025 GMC Sierra 2500 HD AT4X AEV Edition is a purpose-built platform ready for long-distance expeditions and extreme terrain. Built on a high-strength, fully-boxed steel frame, it features revolutionary Multimatic DSSV dampers, which are race-proven shocks offering unparalleled ride control across varying terrain. Complemented by electronic locking differentials, factory-installed AEV skid plates, and winch-capable steel bumpers, this truck is trail-ready straight off the lot.

Its 6.6L Duramax Diesel engine, paired with the Allison 10-speed automatic transmission, delivers 470 horsepower and an astounding 975 lb-ft of torque. With towing capabilities exceeding 18,000 pounds and a payload rating of 2,600 pounds, this Sierra is ready to haul both gear and camper to the ends of the earth.

“For those looking to explore farther, stay off-grid longer, and do it all with unmatched comfort and confidence, the 2025 GMC Sierra 2500 HD AT4X AEV Edition stands at the pinnacle of heavy-duty overlanding right out of the box,” said Matt Feldermann, Overland Expo Ultimate Vehicle Build Project Manager. “Everything we added only enhanced an already adventure-ready platform, making this our most epic Ultimate Build yet.”

The project began at American Expedition Vehicles (AEV) in Michigan, where additional enhancements took the truck from trail capable to expedition elite:

• AEV Salta XD Wheels paired with 37” BFGoodrich All-Terrain KO2 tires
• AEV 37” Tire Clearance Kit
• ComeUp SOLO 12.5rs winch, co-developed with GM
• AEV Snorkel for cleaner, cooler airflow
• AEV Front Bumper Light Bar (prototype) with Vision X Explora offroad lights
• AEV Paint Appearance Package
• Magnaflow stainless steel exhaust for increased efficiency
• Air Lift LoadLifter 5000 Pro suspension kit for camper-readiness

The vehicle’s overlanding prowess is completed with the OEV Back Country slide-in truck camper, offering four-season capability, R8 insulated composite walls, and a robust off-grid system including:

• 220W solar panel and 270Ah lithium battery
• Truma heating/hot water system
• Xantrex inverter, Isotherm fridge, and 20-gallon water tank
• Alu-Cab 270 awning, shower cube, and premium storage solutions

The final build phase took place at Tiny Rig Co. in Southern California, known for its high-end craftsmanship. Its team wired auxiliary lighting, installed a Switch-Pros SP9000 system, and integrated a Midland CB radio for trail communications. Additional comfort and utility accessories include:

• Tackform TRAXX system for in-dash device mounting
• ONWRD Supply Co. seat back organizers
• Viair portable compressor and Rig Ready Systems Jackout HD kit
• Redzone Wireless internet and Zoleo Satellite Communicator for global connectivity

The Ultimate Build will debut at Overland Expo® West, the premier overlanding event in the U.S., hosted in Flagstaff, Arizona, May 16–18, 2025. After touring the country – including stops at the remaining 2025 Overland Expo events and Outdoor Retailer – the Ultimate Build will be auctioned off, with all proceeds benefiting the Overland Expo Foundation. The foundation is dedicated to funding projects that support the overland community and the lands we’re lucky to explore.

For more information, please visit: https://www.overlandexpo.com/ultimate-overland-vehicle-2025/.

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About Overland Expo

Founded in 2009, Overland Expo is the world’s premier event series for do-it-yourself adventure travel enthusiasts. Hundreds of exhibitors of adventure travel equipment, camping gear, bikes, vehicles, and services convene at every Overland Expo event. Each Expo hosts hundreds of session hours of classes, including off-road driving techniques, adventure motorcycling, inspirational programs, roundtable discussions, demonstrations and the Overland Film Festival. Overland Expo is owned and produced by Emerald.

About Emerald

Emerald’s talented and experienced team grows our customers’ businesses 365 days a year through connections, content, and commerce. We expand connections that drive new business opportunities, product discovery, and relationships with over 140 annual events, matchmaking, and lead-gen services. We create content to ensure that our customers are on the cutting edge of their industries and are continually developing their skills. And we power commerce through efficient year-round buying and selling. We do all this by seamlessly integrating in-person and digital platforms and channels. Emerald is immersed in the industries we serve and committed to supporting the communities in which we operate. As true partners, we create experiences that inspire, amaze, and deliver breakthrough results. For more information, please visit www.emeraldx.com.