01
Survey pack envelope
Map enclosure seams, lift points, coolant paths and crush structures.
Acceptance gate
Protection mounts avoid all pack fasteners and deformation zones.
← All Build Plans
Advanced // 28–44 hours // $4,800–$11,500
EV Overland Rig
Underbody protection, recoverable camp loads, and thermal monitoring designed around factory high-voltage boundaries.
Ioniq 5 / Rivian R1T / F-150 Lightning
Remote camp power with measured return reserve
Power ceiling
Factory V2L / onboard power up to platform rating
Protected reserve
20% traction state of charge
Plan fit and specifications
Choose this plan when
- Factory external power output
- Rough-road travel
- High camp-power demand
- Skid coverage
- Pack leading edge and vulnerable coolant runs
- Energy reserve
- 20% SOC minimum before camp loads
- Thermal watch
- Coolant delta and pack inlet temperature
- Recovery
- Rated points accessible with gear installed
- Isolation
- No modification inside HV enclosure
Bill of materials
| System | Specification | Qty |
|---|---|---|
| Skid system | Platform-specific nonconductive-isolated armor | 1 set |
| Load center | Weatherproof GFCI distribution | 1 |
| Telemetry display | Pack thermal and SOC monitor | 1 |
| Recovery kit | Rated soft shackles, boards, compressor | 1 set |
| Camp harness | Outdoor-rated locking power cable | 1 |
Assembly sequence
Build in order. Pass every gate.
02
Install armor
Torque platform brackets in sequence with dielectric isolation where specified.
Acceptance gate
Full steering, suspension and thermal clearances confirmed.
03
Build power branch
Use only the vehicle’s approved outlet or adapter and a protected load center.
Acceptance gate
GFCI trip and ground-fault behavior pass under load.
04
Validate trail state
Test loaded clearance, thermal rise and energy return budget on a controlled route.
Acceptance gate
Return point is reachable with 20% reserve in modeled worst case.
High-voltage safety boundary
- Never drill or weld near the battery enclosure.
- Do not exceed the vehicle outlet’s continuous rating.
- Stop after any underbody impact until the pack is inspected.