Services

Consulting & Technical Services

At Mesa Overland, we love helping people build the rig they’ve been dreaming about — whether it’s a full-blown expedition truck or a simple, ultralight slide-in.

Our founder and lead builder, Blayne, offers consulting in:

Mechanical & chassis selection
Habitat design & engineering
Custom sizing & feasibility
Fabrication planning
Flatbeds, subframes & mounting systems
Interior layouts & space planning
Electrical systems (Victron & Bluetti RV5)
Window/door selection
Materials & workflow strategy

Consulting is billed at our standard shop rate of $125–$175/hr, depending on the work required.

Fully Custom Builds

If you want something that doesn’t exist yet — this is where we shine.

Whether it's:

A uniquely sized flatbed or slide-in habitat
A fully engineered frame-mounted expedition cabin
A highly detailed premium interior
A one-off layout based entirely on your lifestyle and equipment

—we can build it.

Custom Sizing & Advanced Engineering

Custom sizing Phase 1 fee: $1,500
Full custom design after Phase 1 is hourly
Most complete custom design packages average ~$7,500
All custom engineering, CAD, CNC prep, and fabrication planning is $125–$175/hr

These projects take more time, more engineering, and more communication — but the result is a truly one-of-one habitat.

Spec Composite Habitat Models

Our core lineup of pre-engineered Mesa Overland models is ideal for most customers. These models offer faster build timelines, predictable engineering, and excellent value.

They can be built as:

Slide-ins
Flatbeds
Chassis-mounted habitats

Phase 1 – Shell Only

Includes:

Composite structure
Arctic Tern Wildlands door
Internal reinforcement
Engineering & fitment
Optional window and penetration cutouts

Shell pricing typically ranges:

High $20Ks → small slide-ins
$30Ks–$40Ks → most mid-size builds
$50Ks+ → large or monster frames

This is your ultra-strong composite foundation.

Phase 2 – Interiors, Systems, Electrical & Customization

Standard Modifications Package

$2,500 for 20 hours of design & customization, covering:

Plyboo stain colors
Powdercoat colors for cabinetry
Cushion fabrics & upholstery
Minor layout and interior tweaks
Hardware choices
Small refinements

Interior Buildouts (Standard or Custom)

We offer everything from minimal builds to full expedition interiors:

Aluminum-framed cabinetry w/ Plyboo faces
Beds, dinettes, bunks
Galleys & storage systems
Water systems
Heating
Lighting & fixtures
Flooring
MOLLE panels
Accessory mounting

Electrical Systems (Victron & Bluetti RV5)

We can integrate:

Complete Victron Energy systems
The Bluetti RV5 all-in-one system
Solar arrays
12V/120V distribution
Shore power
Monitoring & automation

Phase 2 is your playground — we can do as much or as little as you want.

Standard Model Buildouts – Coming Soon

We’re in the process of releasing a lineup of Standard Model Buildouts — factory-style interior packages that offer extreme value, fast turnaround, and predictable pricing.

These Standard Models take our best layouts, components, and systems and package them into highly streamlined offerings.

Standard Model Pricing

As a general rule of thumb:

A Standard Buildout typically starts at around double the shell price.

Examples:

A $28K slide-in shell → Standard buildout starting around $55K–$60K
A $38K mid-size shell → Standard buildout starting around $75K–$80K
A $50K+ large shell → Standard buildout starting around $100K+

These setups include cabinetry, electrical, basic water systems, lighting, beds, finishes, storage solutions, and smart layout choices optimized from years of builds.

Custom upgrades can still be layered on top as desired.

Windows, Doors & Exterior Options

We install:

Outbound Windows & Doors (Premium)

Best performance
Top-tier thermal efficiency
Highest durability
Clean aesthetic
Strongly recommended

Tern Overland (Arctic Tern) Windows

Lightweight
Budget-friendly
Excellent performance
Perfect for weight-sensitive or cost-conscious builds

Both integrate beautifully with our composite shells.

Subframes, Mounting Systems & Flatbeds

Rail-on-Rail Low-Torsion Subframe (Chassis-Mount)

Our preferred mounting approach for expedition-grade builds.
Allows full chassis flex without stressing the composite structure.

Ideal for:

Ram 4500/5500
Ford F-450/F-550
Medium-duty platforms
Off-road builds

Flatbed Integration

If you have a flatbed, we can:

Add our low-torsion mount system
Or fabricate a custom low-torsion flatbed in-house

Both options create a safe, durable platform for the habitat.

Summary of What We Build

Mesa Overland offers:

Slide-in composite campers
Flatbed composite campers
Full chassis-mounted habitats
Custom-sized habitats
Spec models with customization
Standard Model Buildouts (coming soon)
Expedition-grade interiors
Victron & Bluetti electrical systems
Water, heat & plumbing systems
CNC aluminum cabinetry
MOLLE panels & mounts
Outbound & Tern window/door packages
Rail-on-rail subframes
Flatbed fabrication or adaptation
Mechanical & design consulting

If you can imagine it, we can likely build it