American Expedtion Vehicles Unveils First Ford Truck Build, the FXL Super Duty

American Expedition Vehicles (AEV), a Tier 1 OEM supplier with decades of experience engineering complete vehicle systems, announced the FXL program for Ford Super Duty. Building on the success of AEV’s Prospector Ram conversions and GM HD Bison/AEV Edition programs, the FXL brings proven system-level engineering, advanced manufacturing and validation to the Ford F-250 and F-350 Super Duty platforms, according to company officials in a press release.

Developed from the ground up as a fully integrated vehicle system, the FXL program offers two complementary paths: turnkey AEV Super Duty trucks, fully built and sold through authorized AEV dealerships, and AEV-engineered components for customers who prefer to build their truck over time, noted the release.

A Turnkey AEV Super Duty – Engineered and Built as a Complete Vehicle

The FXL Conversion is designed for customers who want a Super Duty that has been engineered, assembled and validated as a complete AEV vehicle, the company said. Each truck is professionally built at AEV’s 200,000-square-foot production facility in Wixom, Michigan, using OE-style processes and delivered through authorized AEV Dealerships with full warranty coverage.

The FXL name traces its roots to AEV’s original Prospector XL, where XL represents 40 in Roman numerals—a direct reference to the engineering goal that defined the program: fitting 40-inch tires with the least amount of lift possible. AEV says that the same objective drives the FXL for Super Duty, prioritizing increased flotation and off-road capability while maintaining ride quality, stability and confident on-road behavior.

FXL trucks roll on 40-inch BFGoodrich HD-Terrain tires, a new tire developed specifically for heavy-duty applications. Designed to handle the weight, torque and sustained loads of HD trucks, the BFGoodrich HD-Terrain delivers durability and traction without compromising road manners or long-distance performance.

HighMark Fender Flares paired with AEV wheels give the FXL a planted, functional, wide stance that is unmistakably AEV, officials stated. Radar components are integrated directly into the AEV front bumper, ensuring all electronic safety and driver-assistance (ADAS) features remain fully functional. Additionally, the truck is tuned for extended expedition travel while remaining comfortable, predictable and composed for everyday use.

The FXL Family of Parts – The Same Engineering, Available Component by Component

At the foundation of every FXL conversion is a complete line of AEV-engineered components for Ford Super Duty, available individually through AEV’s global dealer network. These are the same parts used on the turnkey FXL conversions and are designed together, validated together and proven as a cohesive system, according to AEV.

AEV components are developed with system-level thinking, accounting for suspension geometry, load capacity, ride quality, tire fitment, electronics integration and long-term serviceability.

FXL component offerings include:

• AEV 4-Inch DualSport Suspension – A premium, dual-purpose suspension system developed from decades of AEV’s OEM-level suspension engineering, featuring AEV-tuned Bilstein shocks, custom-rate coil springs and optimized geometry. The suspension system is designed to balance capability, ride quality and handling while preserving OEM payload and towing capacity.
• AEV Stamped Steel Front Bumper: 3/16- and 1/4-inch stamped steel construction enables complex form with OEM-level fit and finish, featuring a standard winch mount that accommodates up to a 20k-pound winch, integrated ADAS (Advanced Driver Assistance Systems) radar placement, and chassis-mounted recovery points rated to meet or exceed OE standards. The front bumper is also compatible with Ford F-450 and F-550 models. The modular design allows for the addition of a heavy-duty brush guard available in Q3 2026.
• AEV High Clearance Rear Bumper – High clearance design with integrated corner protection and chassis-mounted recovery points for real-world recovery and towing scenarios.
• AEV HighMark Fender Flares – These large AEV fender flares allow for a 40-inch tire fitment with less lift, while maintaining a lower center of gravity and overall vehicle balance. Made from cross-linked polyethylene, these flares are virtually indestructible, the company says.
• 18-Inch AEV Katmai DualSport Wheels – Part of AEV’s DualSport wheel family, Katmai wheels are beadlock-capable for severe-duty use, with the flexibility to run the beadlock ring or operate as a conventional wheel depending on the application. Designed for heavy loads and real-world use, they are tested to exceed load ratings required for HD trucks while maintaining OE-style fitment and serviceability.

AEV says that additional AEV components for 10-lug Ford F-450 and F-550 platforms will be released throughout 2026, beginning in Q3.

The FXL will make its public debut at the 2026 Detroit Auto Show, Jan. 14-25.