Product Ecosystem
OUR PRODUCTS
From flat-packed composite kits to fully integrated camper systems and custom commercial solutions.
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EXPEDITION TRUCK KITS
Ready-to-Assemble Composite Box & Shell Systems for Professional Builders
Engineered for professionals. Built for extremes. Trusted worldwide.
TOTAL COMPOSITES Expedition Truck Kits are precision-engineered composite box and shell systems — not finished campers. These flat-pack panel kits are designed for professional builders, fabricators, and composite specialists who demand precision, durability, and true 4-season performance. Each kit delivers the raw composite panels, extrusions, and hardware needed to construct a custom expedition box or enclosure.
As the first North American company to introduce true 4-season composite expedition kits, TOTAL COMPOSITES has set the benchmark for modern expedition-grade box construction.
With 30+ custom FRP pultrusion profiles, every component is designed to expand and contract uniformly. This eliminates:
- Thermal bridging
- Stress fractures
- Seal failures common in multi-material builds
The result is a true 4-season composite box system capable of handling extreme climates with consistent performance — ready for your custom build-out.
Direct-to-Facility Delivery
All kits are flat-packed and shipped directly to your facility in containers, with logistics and compliance fully managed. This approach simplifies procurement, reduces handling complexity, and ensures that materials arrive ready for immediate assembly.
Built for Professional Applications
TOTAL COMPOSITES Expedition Kits are trusted by builders across North America for overland expedition vehicles, commercial upfits, and custom composite solutions. The system provides a reliable foundation for projects that demand performance, consistency, and long-term value.
Key Features
- German-engineered fiberglass composite panels
- High-density closed-cell PU foam cores (B2 fire rated)
- 100% fiberglass FRP pultrusions (30+ shapes available)
- Non-toxic polyurethane adhesive from Germany
- 2-3 day assembly time
- True 4-season, condensation-free performance
- Custom dimensions and configurations available
- Flat-packed shipping in containers to your door
Build It Your Way
Professional Builder Kits
Flat-packed panel systems shipped directly to your facility. Everything pre-cut and labeled for a 2-3 day assembly turnaround — no welding, no heavy equipment required.
Dealer & Wholesale Programs
Volume pricing available for authorized dealers and fabrication shops. Access technical documentation, assembly guides, and dedicated builder support.
Custom Dimensions
Standard configurations or fully custom panel sets. Our engineering team works with your specifications to deliver kits sized precisely for your truck platform.
Not Sure Which Solution Fits?
Our engineering team can help you choose the right system for your project and build requirements.
TALK TO OUR ENGINEERSTechnical Details — Custom Expedition Kits
Total Composites' custom expedition kit program is the most flexible offering in the composite truck body market. Originating in 2017 as flat-packed panel kits shipped in containers worldwide, the expedition kit program enables commercial builders, professional fabricators, and expedition vehicle manufacturers to construct bespoke overland vehicles using the same composite panel technology that powers the Lynx, Wolf, Bobcat, and Wolverine camper shells.
Kits are custom-quoted using Total Composites' proprietary design template — a set of dimensioned drawings that the customer completes with their desired interior dimensions, wall angles, roof profile, and special features such as pop-top roofs, slide-outs, or expandable sections. Compatible base vehicles include Unimog, Mercedes-Benz Actros, MAN TGE, Iveco Daily 4x4, Land Rover Defender, Toyota Land Cruiser 70-Series cab/chassis, Ford F-550 4x4, Ram 5500, and custom semi-truck platforms.
Panel thicknesses range from 25mm to 75mm depending on the application — thicker walls provide greater insulation values for Arctic or Antarctic-rated builds, while thinner panels reduce weight on lighter chassis without sacrificing structural integrity. All panels use the same German raw materials (VOSSCHEMIE adhesives, Chomarat fiberglass fabrics) as the production camper shells. Expedition kits are also used for composite shipping containers, botanical enclosures, wildlife habitat pods, and mobile laboratory/command units.
Learn more about custom expedition truck body kits, composite body panels for Unimog and Iveco builds, and flatpack expedition vehicle kits shipped worldwide from Total Composites in Victoria, BC, Canada.