Mark & Sarah’s 2026 Polaris Xpedition ADV Build

Mark and Sarah came to us with a clear vision — they wanted an Xpedition built for real adventure. Not just a trail rig, but a machine they can load up, head up north, and do some serious dry camping out of. A rooftop tent is already in the plans, and this car is going to be dialed for that life. We absolutely love building cars with a purpose, and this one delivered from start to finish.

Oh, and it's the first full build we've done on the 2026 Slate Gray color. Once you see it all come together with the powder coat, the Valor wheels, and the DRT Motorsports accessories, you'll understand why we're obsessed with it.

Front End — DRT Motorsports Bumper, MOJAB Offroad Fairlead & Nacho Offroad Lighting

Starting up front like we always do. We went with the DRT Motorsports front bumper — if you've watched any of our builds, you already know we put these on just about every Xpedition that rolls through here. The fit is just right, it works perfectly with the factory winch, and it sets up the front end for everything else you want to do with the car.

On the bumper, we ran the MOJAB Offroad fairlead in charcoal, which happened to match the powder coat perfectly. If you haven't run one of these, it gets rid of the factory magnet and that hook that dangles and scratches stuff up. It's got a built-in hook, the whole thing is super user-friendly, and it just looks clean. We've been running these on builds lately and love them every time.

We also threw the DRT Motorsports grill insert on there to clean up the factory look and tie everything together up front.

For lighting, we went with the Nacho Offroad Quatro lights on the front bumper, and one of our favorite things about these is the daytime running light feature. Any time the key is on, these are lit up — just like the newer style trucks you see on the road. It's a super clean look during the day, and when you fire them up at night, they are absolutely bright. Love what Nacho Offroad is doing with their products.

Suspension — HCR Racing Mid Travel, Shock Therapy & SuperATV Rhino 2.0 Axles

The suspension setup on this one is everything you'd want on a mid travel Xpedition. We went with the HCR Racing mid travel kit — I run these on my own personal car and I love everything about what HCR does. Paired with that, we have the Shock Therapy dual rate spring kit and Shock Therapy Ride Improvement System inside the shocks. That combination is going to make this thing ride really, really well whether they're loaded up for camping or just out on the trails.

HCR also came out with a new complete billet tie rod — and this is worth talking about. They used to do an extension, but now they have a full billet tie rod that is super strong. That's what we put on this car, and it's a serious upgrade for peace of mind out on the trail.

For axles, we went with the SuperATV Rhino 2.0 axles. All the good stuff, all dialed in.

Wheels & Tires — Valor Offroad & Tango 33"

The wheel and tire combo on this car just worked out perfectly. We went with Valor Offroad wheels paired with the Valor Offroad Tango tire in a 33 inch. Since this is a mid travel setup, a 33 inch Tango is really the sweet spot — this tire runs a little big, so it's the perfect fit for this application. If you ask me, it's the best stance you can get on a mid travel Xpedition.

And here's one of those moments where everything just comes together — the center cap color on the Valor wheels happened to match the Slate Gray on the car right out of the box. We got lucky on that one, and it looks absolutely dialed.

Exterior Details — DRT Motorsports Mesh, Marshin Whips & B's Fab Mounts

We powder coated all the mesh panels, the suspension, and all the accent pieces in gray to match the Slate Gray paint. The DRT Motorsports side air intake mesh and DRT Motorsports rear fender mesh are on there, powder coated to match, and they just clean up the whole look of the car. We kept the factory mirrors and threw the DRT Motorsports mesh in those too.

For whips, we kept it practical — a two-foot Marshin Whips setup mounted with B's Fab whip mounts. Short enough that they're not catching every tree on the trail, but they've got lights on them for visibility when they're out camping or riding in a group. Just the right amount.

Rear End — Elektric Offroad Designs Bumper, XTC Power Products License Plate & Grab Handle

Around back, we went with the Elektric Offroad Designs rear bumper, powder coated all the panels to match the rest of the car. It just ties the whole exterior together when everything is powder coated consistently — front to back, it's cohesive and clean.

For the license plate, we used the XTC Power Products lighted license plate frame — all lit up with LEDs, keeps them legal out there. The DRT Motorsports exhaust cover is powder coated with the badge and mesh to match.

One thing I really like on this build is the Elektric Offroad Designs rear glass handle. It mounts dead center on the rear glass, so instead of reaching to the corner of the window to get it open, you grab it right from the middle. The angle they designed into it makes it sit flush and look like it belongs there. Really clean, really functional.

Interior — Jump Lug & Kill Switch, B's Fab Door Extenders & KC HiLiTES Dome Lights

Inside, we kept it functional and smart — which makes total sense for a car that's going to be used for dry camping.

The big one is our Jagged X Offroad Jump Lug & Kill Switch Kit. This thing is a game changer for campers. The jump lug means if they ever need to jump the car, they can do it right from here — no unbolting seats. The kill switch is the big deal for them though. When they're out camping and they're done using the car for the day — or they want to leave it and go on a hike — they hit that kill switch and nothing is draining their battery. It also gives them some security. If somebody walks up to the car and messes around with it, they're probably not going to know what that switch is. Super clean, super smart.

We did the B's Fab extended rear door limiting straps — these are our number one seller for a reason. If you've ever tried to get into the back of an Xpedition without them, you already know why. They're absolutely necessary.

For lighting inside, we went with KC HiLiTES diffused dome lights on a custom-built plate, installed in all three positions and wired to a single XTC Power Products dome light switch. Hit one switch and all three light up — plenty of light to see everything in the back when they're digging through the cargo area at the campsite.

For all the switches throughout the car — whip, rock lights, pod lights, dome light — we used XTC Power Products rocker switches across the board. Everything is clean, labeled, and consistent.

Complete Parts List

Bumpers & Exterior Protection
- DRT Motorsports Front Bumper
- Elektric Offroad Designs Rear Bumper
- DRT Motorsports Grill Insert
- DRT Motorsports Exhaust Cover

Fairlead & Recovery
- MOJAB Offroad Aluminum Recessed Winch Shackle with Fairlead Kit (Charcoal)

Lighting
- Nacho Offroad Quatro Lights
- KC HiLiTES Diffused Dome Lights

Suspension & Axles
- HCR Racing Mid Travel Kit - Contact Us
- HCR Racing Billet Tie Rods - Contact Us
- Shock Therapy Dual Rate Spring Kit
- Shock Therapy Ride Improvement System
- SuperATV Rhino 2.0 Axles

Wheels & Tires
- Valor Offroad Wheels
- Valor Offroad Tango Tire (33")

Mesh & Accent Panels
- DRT Motorsports Side Air Intake Vent Mesh Set
- DRT Motorsports Rear Fender Mesh Set

Whips & Mounts
- Marshin Whips (2ft)
- B's Fab Whip Mounts

Rear Accessories
- XTC Power Products Lighted License Plate Frame
- Elektric Offroad Designs Rear Glass Handle

Interior
- Jagged X Offroad Jump Lug & Kill Switch Kit
- B's Fab Extended Rear Door Limiting Straps
- XTC Power Products Dome Light Rocker Switch
- XTC Power Products Rocker Switches (Whip, Rock Lights, Pod Lights)

Build Your Own Polaris Xpedition

If you want to dial in your own Xpedition like this, check out all of our Polaris Xpedition ADV parts and accessories or reach out to us and we'll put together a build plan that fits your riding style. We love building these things and we'd love to help you get yours dialed in.