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I got a call back from a gentleman at Thor who answered many of my questions.
First, there doesn't appear to be any flexibility to order chassis options. Thor orders chassis in large lot sizes equipped a certain way, and it's not possible to order the extra heavy duty alternator option, or smaller V8 engine, aluminum wheels, etc. He didn't know the exact alternator size but knows all Axis/Vegas get the same. He said dealers can often handle modifications like aftermarket wheels.
Regarding use of E-450 chassis, he confirmed previous reports that it's due to environmental requirements. He "thinks" that using the E-350 may have required going with the 5.4 V8, and that they don't think it's strong enough. When asked, he said he wasn't aware of plans for larger Axis/Vegas models or with two slides (due to the heavier-duty E-450 chassis). I figure he wouldn't have told me anyway even if he knew.
For now options are limited to the ones we know about: Extra TV, larger 15,000 AC, colors, etc. Significant customization in this case is not practical, being outside the scope of what they do.
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