Texas Customer’s DIY Polaris Xpedition Build – One of the Cleanest We’ve Seen

When Kent from Texas reached out to us, he had a clear vision: build a Polaris Xpedition that matched the quality of our shop builds, but do most of the work himself. After checking out our content online, he compiled a complete parts list, ordered everything from Jagged X, and got to work in his garage. Ninety percent of this build was completed in Texas before Kent shipped his Xpedition to Phoenix for us to handle the finishing touches and final dialing.

The result is one of the cleanest Polaris Xpedition builds we've had roll through our doors - and it proves that with the right parts and determination, you can create a professional-grade build at home.

Front End Protection and Lighting

Starting at the very front, Kent installed a MOJAB Offroad Front Fairlead with Hook - hands down the cleanest hook setup available for the Xpedition. American-made with a lifetime warranty, this fairlead eliminates the annoying rattle that comes with stock setups while providing clean winch access. It's become a staple on our builds for good reason.

The DRT Motorsports Front Bumper is our go-to choice for 90% of Xpedition builds, and Kent's is no exception. What makes his unique is the custom powder coating - instead of DRT's standard textured crinkle coat finish, Kent went with smooth satin black. He also powder coated all the mesh grills in charcoal and had the DRT logos custom painted in red to match his theme throughout the build.

For lighting, Kent chose a combination of Baja Designs Squadron Pro lights in the center of the bumper with Baja Designs LP4 lights mounted on top using custom powder-coated brackets. This setup provides excellent visibility for night runs and trail riding.

Kent also added the DRT Motorsports Grill with the same powder coat combination - smooth satin black with charcoal mesh and red logo accents. The attention to detail throughout this build is what sets it apart.

Suspension and Steering Setup

The suspension on Kent's Xpedition is built around a JRI Suspension Mid Travel Kit - one of our absolute favorite suspension upgrades. JRI recently rebranded as Cedar Suspension Company (based out of Cedar, Utah), and they're continuing the same high-quality, rider-focused approach. We run one of these kits on our shop Xpedition, and the durability and performance are exceptional. If you're looking at suspension options, definitely check out their new Instagram page @cedarsuspensionco.

Supporting the JRI kit, Kent installed the complete Shock Therapy package including:

• Shock Therapy Dual Rate Spring Kit
• Shock Therapy Ride Improvement System
• Shock Therapy Sway Bar Links (front and rear)

For the front end, he chose Black Ops Ball Joints - a product we've sold hundreds of with virtually zero warranty claims. Black Ops backs these with a lifetime warranty on normal use, and in our experience, they're built to last.

The Super ATV Powder Coated Tie Rod Kit rounds out the steering setup. Unlike many mid-travel kits that use tie rod extensions, Super ATV provides a complete replacement tie rod. Kent had his powder coated black to match the theme, and it's a much more durable solution than running extensions.

Kent also equipped his Xpedition with Rhino 2.0 Axles, which we use on all our mid-travel builds. These are essential when you're adding width and power to these machines.

Brakes and Wheels

One upgrade that really sets Kent's build apart is the TPR Industries Big Brake Kit. While you can't see much of it in photos due to the wheel design, this system provides significantly improved stopping power - especially important when you're adding weight with all these accessories and running in technical terrain.

For wheels and tires, Kent went with Raceline Wheels that he custom powder coated - specifically the rings - to match the red accent theme throughout the build. He wrapped them in 32-inch BFG tires, which is a great size for the Xpedition platform - aggressive enough for serious terrain without sacrificing too much on-road manners.

Roof and Upper Accessories

Up top, Kent installed DRT Motorsports A-Pillar Light Brackets with more Baja Designs LP4s, all powder coated red to match the theme. But here's where he did something we haven't seen before - he added small Baja Designs S1 side shooter lights hidden in the A-pillar area. These provide excellent ditch light and side lighting for night runs, and they're tucked away nicely so they don't interfere with the clean look.

DRT Motorsports Mirrors were custom powder coated to match, and Kent mounted a Jagged X Offroad Starlink Mini Mount on the roof that's hardwired through Switch Pros. Being able to have reliable internet anywhere he travels in Texas is a game-changer for longer trips.

Marshian Whips with Viper Machine Whip Mounts handle flag duties, and all the DRT accent panels throughout the build were powder coated to keep that consistent red and black theme.

Rear Bumper and Bed Setup

The rear of Kent's Xpedition features a DRT Motorsports Rear Bumper with integrated backup/work light and an XTC Power Products License Plate Frame. The AJK Offroad Exhaust Cover was powder coated to match everything else.

One must-have accessory Kent added is the DRT Motorsports Camera Extension for the rear bumper. When the factory backup camera sits flush with the bumper, it often catches too much of the bumper itself in the frame. This extension moves the camera out and allows for much better adjustment and field of view - it's become one of our most recommended accessories.

Inside the bed, Kent installed an AJK Offroad Bed Tray with space for a cooler and a ROAM storage box. The DRT Motorsports Rear Spare Tire Carrier mounts above the storage box and holds a full-size spare tire - crucial for anyone doing serious backcountry riding.

Kent also added Blade's Custom Decking throughout the bed area for a premium finished look, and a Chupacabra Fire Extinguisher Mount with a 2.5-pound extinguisher. This is one of Chupacabra's newer products, and they offer it in both 2-pound and 2.5-pound sizes with low-profile clamps that fit perfectly on the Xpedition's rear structure.

Interior Build - Where This Build Really Shines

This is where Kent's Xpedition build truly stands out. The interior is one of the cleanest we've seen, period.

Blade's Custom Decking covers every surface - doors, dash accents, floor mats (with Kent's business name embroidered), and rear panels. Kent went with gray decking with red accents throughout, creating a cohesive look that ties the whole interior together.

The Triple X Heated and Cooled Seats are upholstered in gray and red to match, with perforated centers for the cooling function. These seats are a massive comfort upgrade over stock, especially for longer rides in hot Texas summers or cold winter mornings.

All the DRT Motorsports interior accessories were powder coated in black and red:

• Passenger grab handle
• A-pillar grab handles
• Door handles

The Viper Machine Shifter features a red shift knob that pops against the gray and black interior. Kent also installed a Pro R steering wheel with Switch Pros mounted in the center for easy access to all his lighting and accessories.

What's particularly impressive is that Kent did all this custom work before Polaris released the 2026 Xpeditions with red factory accents - he was ahead of the curve on the color scheme.

The XTC Power Products Turn Signal Kit is powder coated red and includes hazard lights, horn, and self-canceling turn signals - a must-have for anyone riding in areas where street legality matters. Kent mounted it in a clean, accessible location on the dash.

Above, a plush suede headliner adds a premium touch, along with factory Polaris visors. LITT Industries Dome Lights (switched from the dash) provide interior lighting, and in the rear, Kent installed MacDermid Design Molle Panels underneath the rear seats with a first aid kit mounted for quick access.

Chupacabra Headset Hangers and Axia Headset Mounts keep the Rugged Radios M1 communication system organized and accessible.

One particularly smart addition is the jump lug kit with cutoff switch mounted low in the interior. Kent travels frequently, and being able to completely cut power to the vehicle prevents battery drain when the Xpedition is sitting for extended periods.

The B-Fab Door Extensions are our number one selling accessory for good reason - they give you about six extra inches when opening the doors, making entry and exit dramatically easier, especially when loading kids, car seats, or gear into the rear seats.

Protection and Rock Sliders

For protection, Kent installed DRT Motorsports Inner Fender Guards to keep mud, rocks, and debris out of critical areas. He paired these with Factory Polaris Low Pro Rock Sliders - a clean look that provides solid protection without adding excessive width to the machine.

The Complete Build List

Here's everything on Kent's Polaris Xpedition:

Suspension & Steering:

• JRI Suspension Mid Travel Kit (Cedar Suspension Co.)
• Shock Therapy Dual Rate Spring Kit
• Shock Therapy Ride Improvement System
• Shock Therapy Sway Bar Links (Front & Rear)
• Black Ops Ball Joints
• Super ATV Powder Coated Tie Rod Kit
• Rhino 2.0 Axles

Brakes:

• TPR Industries Big Brake Kit

Wheels & Tires:

• Raceline Wheels (Custom Powder Coated)
• 32" BFG Tires

Front Bumper & Lighting:

• DRT Motorsports Front Bumper (Custom Powder Coat)
• MOJAB Offroad Front Fairlead with Hook
• DRT Motorsports Grill (Custom Powder Coat)
• Baja Designs LP4 Pro Lights (x2)
• Baja Designs Squadron Pro Lights (x2)
• DRT Motorsports A-Pillar Light Brackets (Custom Powder Coat)
• Baja Designs LP4 Pro Lights - A-Pillar (x2)
• Baja Designs S1 Side Shooter Lights

Rear Bumper & Bed:

• DRT Motorsports Rear Bumper
• DRT Motorsports Camera Extension
• XTC Power Products License Plate Frame
• AJK Offroad Exhaust Cover (Custom Powder Coat)
• AJK Offroad Bed Tray
• DRT Motorsports Rear Spare Tire Carrier
• ROAM Storage Box
• Blade's Custom Decking - Bed
• Chupacabra Fire Extinguisher Mount (2.5 lb)

Interior:

• Triple X Heated & Cooled Seats (Gray/Red Custom)
• Blade's Custom Decking - Full Interior
• DRT Motorsports Passenger Grab Handle (Powder Coat)
• DRT Motorsports A-Pillar Grab Handles (Powder Coat)
• DRT Motorsports Door Handles (Powder Coat)
• Viper Machine Shifter with Red Shift Knob
• Pro R Steering Wheel with Switch Pros
• XTC Power Products Turn Signal Kit (Powder Coat)
• Rugged Radios M1
• Factory Polaris Ram Mount with Phone Holders
• Suede Headliner
• Factory Polaris Visors
• LITT Industries Dome Lights
• MacDermid Design Molle Panels
• Chupacabra Headset Hangers
• Axia Headset Mounts
• Jump Lug Kit with Cutoff Switch
• B-Fab Door Extensions

Exterior Accessories:

• DRT Motorsports Mirrors (Custom Powder Coat)
• DRT Motorsports Accent Panels (Custom Powder Coat)
• DRT Motorsports Inner Fender Guards
• Factory Polaris Low Pro Rock Sliders
• Marshin Whips
• Viper Machine Whip Mounts
• Jagged X Offroad Starlink Mini Mount (Hardwired)

Custom Powder Coating:

• Smooth Satin Black (Bumpers, Interior Accessories)
• Charcoal (Mesh Grills)
• Red (Logos, Accents, Light Brackets)

Building Your Own Xpedition

Kent's build proves that with the right parts and some determination, you can create a professional-grade Polaris Xpedition build at home. We ship complete parts packages nationwide, and we're always happy to help you spec out a build that matches your riding style and budget.

Whether you want to tackle the install yourself like Kent did, or you'd prefer to have us handle the entire build in-house at our Phoenix shop, we can make it happen. Every Xpedition owner has different needs - some prioritize suspension and handling, others want luxury and comfort, and many want the best of both worlds.

If you're considering an Xpedition build, contact us and let's talk through what you're looking for. We can put together a complete parts list, answer any installation questions, and make sure you're getting exactly what you need to build your dream machine.

Want to see more Xpedition builds? Check out our YouTube channel where we document every build that comes through the shop, or follow us on Instagram for daily updates on current projects.

Ready to build your Xpedition? Shop Polaris Xpedition Parts or Contact Us for a custom build quote.