Custom Chevy 6500 Adventure Builds

Build Your Ultimate Off-Road Adventure Rig

If you’re looking at a Chevy 6500, you’re probably not looking for a normal “camper build.” You’re looking for a rig that can carry real systems, real supplies, and real comfort, and still feel solid when the road gets rough.

At Exploration Vans, we build custom Chevy 6500 expedition vehicles for people who want to travel farther, stay out longer, and stop worrying about what their vehicle can handle.

Request a Quote

The Chevy 6500 Is a True Blank Canvas

The biggest difference with the Chevy 6500 is that it starts as a chassis cab. You are not squeezing a build into a pre-shaped van body or trying to make a pickup bed “work.” You are starting with a strong commercial foundation that is meant to be built on.

That matters because the people drawn to this platform usually have a clear goal. More range. More payload. More capability. More autonomy. The 6500 gives us the room to design your living space, storage, and systems the right way, without constantly compromising around limitations.

Why Choose a Custom Chevy 6500?

Heavy-Duty Capability

With up to 23,500 lbs GVWR and 37,500 lbs GCWR, the Chevy 6500 handles the heaviest custom builds, full amenities, and towing needs with ease.

Easy Maintenance

Commercial-grade components and widespread dealer network mean parts and service are readily available wherever your adventures take you.

Proven Power

Duramax 6.6L turbo-diesel V8 delivers 350 hp and 750 lb-ft of torque paired with Allison 6-speed automatic transmission for legendary performance.

4x4 Available

Available in 4x2 or 4x4 configurations with up to 50-degree wheel cut for exceptional maneuverability and off-road capability for remote exploration

Upfit-Friendly by Design

Chassis cab design with clean frame rails and multiple wheelbase options (165-243") makes upfitting simple. Built from the factory to be customized.

Cab Options

Choose Regular Cab (3 PAX) or Crew Cab (6 PAX) depending on your needs, perfect for solo adventurers or family expeditions.

Uncompromising Quality in Every Custom Build

When you choose Exploration Vans for your custom Chevy 6500 build, you're choosing a team that refuses to cut corners. Every conversion is meticulously crafted using premium materials and time-tested techniques.

Our builds feature marine-grade components, aerospace-quality insulation, and custom furniture built to withstand decades of use. We don't just build vehicles—we create heirloom-quality expedition rigs.

Explore Features

Factory-Built for Customization

The Chevy 6500 HD is not just customizable. It is designed from the ground up as a chassis cab built specifically for upfitting. Clean top-of-rail frame design, dual-side PTO access, and auxiliary power switches make professional-grade custom builds straightforward and reliable.

Multiple wheelbase options ranging from 165 to 243 inches allow us to create the right proportions for your build, whether that means a more compact adventure rig or a spacious full-time home on wheels. The single-piece straight frame rails provide the structural integrity needed to support heavy expedition equipment.

Chevy 6500 HD Specifications

23,500

lbs Max GVWR

350

HP Duramax 6.6L

750

lb-fts Torque

37,500

lbs Max GCWR

Explore our portfolio of custom Chevy 6500 builds

View Portfolio

Our Custom Build Process

  • Step 1. Consultation

    Schedule a 30-45 minute conversation to discuss your ideas, potential spec and layout ideas, and create a rough pricing and timeline estimate for your project.

    Close-up of a silver Ford Transit van with black off-road tires, black front bumper, and black side step, parked on a rocky dirt surface under a clear blue sky.

  • Step 2. Security Deposit

    Once you’ve decided to move forward, a security deposit secures the next available production slot on our build calendar. You will then be introduced to your Design Consultant.

    Side view of a white camper van with a black ladder attached, part of the rear wheel and tire visible, parked on grass with trees reflected in window, under a partly cloudy sky.

  • Step 3. Design.

    Working with your Design Consultant to hone in the features and components needed to realize your goals and complete a final parts list and estimate for your approval.

    Silver camper van parked outdoors with a black ladder on the side, trees in the background, and the sun reflecting off the window.

  • Step 4. Production

    This is the best part! When you drop your vehicle off with us, 60% of your estimated build cost is required. During production your Production Foreman will keep in touch throughout the build process.

    A vehicle with a spare tire mounted on the rear, parked on grass next to orange flowers and green plants.

  • Step 5. Testing and Multimedia

    Once your build is completed every function and component will undergo testing to ensure peak functionality. We will also compile a multimedia suite for our own marketing as well as your own personal use.

    A wooden cabinet or piece of furniture with metal hardware and plastic covering on a handle.

  • Step 6. Delivery

    Once your project has passed the testing phase, your Production Foreman will reach out to arrange a pickup date to walk you through every system and feature of your new van. Before leaving, your remaining project balance will be paid in full.

    Gray van parked outdoors on a fall day with an orange tree in the background and cloudy sky.

Ready to Build Your Custom Chevy 6500?

Let's turn your vision into reality. Contact Exploration Vans today to start your custom build journey.

Schedule Consultation

FAQs: Custom Chevy 6500 Chassis Cab and Upfitting

  • The Silverado 6500 HD is a chassis cab—essentially a bare truck frame with a cab. Unlike a traditional pickup, it's designed from the factory to have a custom body built on it. This gives you complete freedom to create the exact living space, storage, and layout you envision without compromising the truck's structural integrity.

  • Typical build times range from 6-12 months, depending on complexity and customization level. We'll provide a detailed timeline during your consultation and keep you updated throughout the process.

  • Yes! The Silverado 6500 HD is available in both 4x2 (rear-wheel drive) and 4x4 configurations. For serious off-road and overlanding builds, we recommend the 4x4 option, which provides exceptional capability on challenging terrain while maintaining the truck's impressive 50-degree wheel cut for maneuverability.

  • Custom Chevy 6500 builds typically range from $200,000 to $400,000+, depending on size, features, and level of customization. We work with various budgets and can help you prioritize features that matter most.

  • We can handle the entire process, including sourcing the chassis in your preferred configuration (Regular Cab vs. Crew Cab, 4x2 vs. 4x4, wheelbase length). Alternatively, if you already own a Chevy 6500 chassis, we're happy to work with your existing vehicle and can even handle any modifications needed before the upfit begins.

  • Absolutely! We encourage clients to visit our Southern California facility during the build. It's exciting to see your custom Chevy 6500 come to life, and we can make real-time adjustments if needed.