“As my family has grown, I needed a truck more capable than my Chevy 3500 dually on 40s to haul a bigger camper, bigger trailer, and bigger toys, while still getting off pavement and away from things,” says Tyler Zimmer, the owner and builder of this massive, multifunctional 2024 Chevy 6500 HD 4×4.
The truck was transformed from stock in just eight weeks. Tyler, an aircraft engineer, says, “I handled all the labor, with the help of my wife and kids, except the bedliner, which was sprayed by Off The Grid Motorsports, and I had a few buddies help hold the roll cage tubes while I tacked them in place.” He also notes that Cris Payne at Truck Guru served as the build manager.
Designed To Be Multifunctional, Like A Swiss Army Knife
Tyler offered an overview and reasoning behind the truck’s multifunctional design. “We have young children, and we love going camping and wheeling as a family. This truck lets us still get far from pavement and we can take the big toys with us for harder wheeling. This truck is designed to be like a Swiss Army Knife. Sometimes we put my 1-ton Jeep LJ or my wife’s sixth-generation Bronco on the flatbed if we want to run cross country for some wheeling and not worry about dragging a trailer with us. At other times we put a Lance 1172 double-slide camper on the bed and load the Jeep and UTV in the enclosed trailer for a long stint off-road. Other times we just load the camper and go camping and slow wheeling to places like Tuweep or the old Mojave Road.”
L5P Duramax, Bigger Turbo Coming Soon
The 2024 Chevy 6500 HD 4×4 is powered by the factory L5P Duramax turbodiesel V8. It features the factory optional belt drive air compressor and dual alternators. Airflow is upgraded with a Banks Power Ram-Air intake, Monster-Ram Turbo Inlet Elbow, along with custom intercooler piping and intake manifold porting. Oil cooling is improved with a Banks oil pan. Tyler keeps tabs on the engine with Banks gauges, and he replaced the factory alternators with higher-output Mechman 500-amp units.
Tyler says the engine remains relatively stock, but he wants more power. “Pulling a load in the mountains on 44-inch tires is challenging,” he says. To increase its output, he plans to add a larger turbo and a tune.
Allison Six-Speed Transmission, Meritor Transfer Case
Backing the Duramax is an Allison 2750 six-speed automatic transmission. Cooling is improved with a Banks Ram-Air pan. Power flows through a Meritor 3203 gear-drive transfer case, then to the axles via a pair of 1650 Series U-joint driveshafts.
Dana Super 60 Up Front, Locked Dana S140 Out Back
Up front sits the factory Dana Super 60 axle. Out back is the optional Dana S140 Series axle with a factory Eaton Detroit Locker and 47-spline axle shafts. The axles remain stock for now, but changes are coming. Tyler plans to add a selectable locker to the front differential, upgrade to 300M axle shafts, and regear both axles to a 5.38:1 ratio.
Hydraulic Rear Suspension
The front suspension is stock for now. However, the rear features a computer-controlled, hydraulic LiquidSpring five-link setup. Tyler reports that the LiquidSpring suspension transformed the truck. “Stock, these 6500s ride so incredibly rough that I was afraid my truck camper was going to crack. With the LiquidSpring, the ride is amazing.”
The Chevy rides on 315/80R22.5 Toyo M325 tires, mounted to 8.25-inch-wide American Force Rewind wheels.
Custom Aluminum Bed, Over 30 LED Lights, And More
The Chevy sports an extensive list of additional modifications. Highlights include an exocage, Patriot Liner-protected body, and a Buckstop Truckware front bumper fitted with a 22,000-pound-capacity Warrior winch. The custom aluminum bed was developed in partnership with Protech and packs more than 90 square feet of lockable storage. A bed-mounted Warrior 25,000-pound-capacity winch can pull disabled vehicles up rear ramps and onto the flatbed.
The truck is outfitted with more than 30 Rigid Industries LED lights, a Rhino Rack roof rack, and a refrigerator. It also runs a Gen-Y Boss hitch, along with side-mounted Gen-Y hitches that serve as anchor points or mounts for bike racks, grills, and more, all secured with BOLT Locks. Additionally, there’s a standalone electrical system designed to support a 1,300-watt camper solar setup with four Epoch lithium-ion batteries totaling 1,200 Ah. Finally, there’s an onboard Miller welder and plasma cutter with a full complement of tools.
Inside, the cab benefits from double-layer sound deadening using spray foam and 3M Thinsulate insulation.
Headed To King of the Hammers And Overland Expo
What’s next for the truck? Well, Tyler is planning to drive it to several 2026 off-road events including King of the Hammers and Overland Expo. He’s looking forward to knocking the tire shine off and he expects it to soon wear some proper rock rash.
Photos by Dale Martin, Tyler Zimmer, and Rick Brian
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