Does anyone have any experience building an overlander out of the 1500 Rebel? If you wouldn't do the Rebel why? I'm thinking hard about it and I think I'll be picking the EcoDiesel. Why is that a good pick, if it's not why pick the Hemi over it? I'm also interested in any parts recommendations, by brand/model, or function. Thanks.
I think you need to consider your use case first - you expecting to go for 300+ miles off road and with limited fuel availability? Trailering, slide-in camper, shell? What sorts of extra weight?
If payload and distance per tank are concerns, the PW starts to fall out of the equation pretty quick. As someone already stated above, the eco diesel will likely give you your most distance per tank, but payload will likely suffer (disclosure, I didn't research eco diesel payloads). Are the trails you're looking to get on tight/have tons of switch backs? 2500/3500s may fall out of the equation then.
I have a PW because payload isn't a concern for me and I've got a couple of 20L jerry cans to hold me over for fuel (in)efficiency reasons. It's also my daily and my commute is like 4 miles with no highway (not good for modern diesels). If I was doing serious long distance overlanding, I'd have a 3500 diesel and build it out appropriately; but that's likely overkill for most.
OA
Edit: the eco diesel is a 20lb payload hit over the 5.7 hemi- that's a no brainer to go ecodiesel there (1720 vs. 1740lbs). My power wagon payload is 1420lbs. A diesel 3500 is in the high 3k range.