American Expedition Vehicles has spent years earning its stripes in the off-road world. The company's work on Jeeps, Rams, and GM trucks has made it a household name among folks who take their weekend adventures seriously. Now, they're turning their attention to Ford for the first time with a build that's bound to turn heads—the FXL conversion for the 2026 F-250 and F-350 Super Duty.
This isn't just another lift kit slapped onto a truck. AEV has taken the same approach they've used on builds like the Ram Prospector, creating a complete conversion program that transforms the Super Duty into an off-road beast while keeping it civilized enough for the daily commute. The result is a truck that can roll over boulders on Saturday and still park comfortably at the office on Monday.
The Big News: 40-Inch Tires
The name FXL isn't just marketing speak. Those Roman numerals translate to 40, which represents the most eye-catching feature of this conversion: the ability to mount massive 40-inch tires. Getting rubber that size under a Super Duty takes more than just wishful thinking. AEV developed a 4-inch DualSport suspension system specifically for this build, using custom-tuned Bilstein shocks paired with specially rated coil springs.
What makes this suspension setup different from the typical lift kit is the engineering behind it. AEV didn't just jack the truck up and call it a day. They revised the entire geometry to maintain the Super Duty's legendary payload and towing capabilities. That means you're not sacrificing the truck's work credentials to gain off-road capability—you get both.
The suspension works hard to deliver a comfortable ride whether the truck is loaded down with gear or running empty. It's the kind of detail work that separates a professional conversion from something cobbled together in someone's garage.
Built to Take a Hit
The FXL package includes front and rear bumpers that serve real purposes beyond looks. The stamped steel front bumper can accommodate a winch rated up to 20,000 pounds, which is serious recovery capability when things go sideways on the trail. AEV also made sure the bumper design properly houses Ford's advanced driver assistance system radar, so all those modern safety features keep working as intended.
Around back, the High Clearance Rear Bumper does what its name suggests—it keeps the truck from getting hung up on obstacles when the terrain gets rough. Both bumpers are constructed from stamped steel rather than lighter materials, giving them the durability needed for actual use rather than just parking lot posing.
The HighMark fender flares handle the job of covering those 40-inch tires while adding some visual muscle to the truck's profile. These aren't the cheap bolt-on plastic pieces that crack in the cold. They're designed to work with the complete package and stand up to the kind of abuse that comes with off-road use.
Wheels That Mean Business
AEV developed a specific wheel for this build called the Katmai DualSport. These 18-inch wheels measure 18x10 with a -13mm offset, which translates to roughly 5 inches of backspacing. That might sound like technical jargon, but what it means is the wheels sit in exactly the right spot to work with 40x13.50R18 tires, the HighMark flares, and the Super Duty's chassis without causing clearance issues.
The wheels are drilled to match the 8x170 bolt pattern that F-250 and F-350 trucks use from the factory. What makes them particularly interesting is their beadlock capability. Owners can run them as standard wheels, or they can install an optional protection ring where a beadlock ring would go. For those unfamiliar, beadlocks are essential for serious off-roading because they prevent tires from slipping off the rim when running low air pressures in sand or rocks.
AEV isn't stopping with the lighter Super Duties either. They're working on 10-lug versions of the Katmai DualSport wheels for F-450 and F-550 trucks, with those expected to become available in the third quarter of this year. The stamped steel front bumper will work on those bigger trucks too, and there's an optional heavy-duty brush guard coming that should be ready around the same timeframe.
Two Ways to Buy
AEV structured the FXL program to work for different buyers. Those who want the complete transformation can order the full package through authorized AEV dealers. The complete conversion includes everything mentioned above, plus a set of BFGoodrich HD-Terrain T/A KT tires in that 40x13.50R18 size with Load Range F rating. These tires are designed specifically for heavy-duty trucks and can handle the weight and demands of a Super Duty.
The complete package also adds FXL body side graphics, AEV-branded fender vents, and an AEV badge on the tailgate. These finishing touches let everyone know this isn't just another lifted truck—it's a professionally engineered conversion with proper backing.
For folks who prefer to build their trucks piece by piece, AEV will sell the components separately. This approach lets owners customize their builds based on their specific needs and budgets. Maybe someone only wants the suspension and wheels, or perhaps they're after the complete package but want to install it themselves. The modular approach provides flexibility.
Where It's Built
The complete FXL conversions will be assembled at AEV's facility in Wixom, Michigan. This isn't some fly-by-night operation in a strip mall somewhere. AEV has invested in proper facilities and trained technicians who know these trucks inside and out. Each complete conversion comes with a three-year, 36,000-mile warranty backed by AEV, which provides peace of mind that a backyard build simply can't match.
Buyers will take delivery through AEV's network of authorized dealers, ensuring there's local support and service available. This dealer network is part of what makes AEV conversions attractive to buyers who want professional modifications with proper support after the sale.
See It in Person
The 2026 Ford Super Duty AEV FXL will make its public debut at the 2026 North American International Auto Show in Detroit. The show truck includes a few extras that won't be part of the standard package, including AEV embroidered headrests and those optional protection rings on the Katmai DualSport wheels. These additions give people a sense of what's possible with the platform.
AEV mentioned they'll offer one leather interior package for lower trim level trucks, but they expect most FXL orders to come on premium level Super Duties that already have leather interiors. This makes sense given the investment required for the conversion—buyers are likely starting with well-equipped trucks.
The Bottom Line
While AEV hasn't released official pricing yet, industry observers expect the complete FXL conversion to land somewhere in the low $20,000 range. That's not pocket change, but it's in line with what professional-grade conversions cost. The question for potential buyers is whether that investment makes sense compared to piecing together parts from various manufacturers or attempting a similar build independently.
What AEV brings to the table is integration. Everything works together because it was designed that way from the start. The suspension geometry accounts for the bigger tires. The wheels are sized correctly for the offset needed. The bumpers maintain factory safety features. There's something to be said for that level of coordination, especially when the alternative might mean troubleshooting compatibility issues or discovering problems only after installation.
The Ford Super Duty has long been a favorite among people who need a truck that can handle serious work. Adding AEV's off-road expertise to that foundation creates something that should appeal to buyers who want the best of both worlds—a capable work truck that can venture far beyond the pavement when the workday ends.
For those who've watched AEV's work on other brands over the years, this Ford build represents a natural expansion. The company has proven it can create conversions that maintain factory reliability while adding genuine capability. Whether that formula translates to the Blue Oval faithful remains to be seen, but based on what AEV has delivered before, the FXL program looks like it's starting on solid ground.
Anyone seriously interested in seeing what all the fuss is about should plan a trip to Detroit for the auto show. Pictures only tell part of the story, and there's no substitute for seeing these trucks in person, especially when those 40-inch tires are involved. They're the kind of thing that needs to be experienced to fully appreciate.
