7.3L Powerstroke Motovan Project.

[225]

Spray them with a good anti-rust lubricant like Fluid Film. Only one of the four works on my van, although the locksmith rebuilt one for about $5.

I cut the side off for easy removal. So they're trashed now.

Neat project!

Does that mean you end up with a little cubby hole above the front seats? Could be a handy place for additional storage.

I do. It's a 18" high x 4 wide area. I plan on housing the breaker panel and additional storage.

What about the roof cage? Are you going to install that?

No. They had that becuase it would have passengers in the rear of the van. Since I won't, it takes up too much headroom. Plenty of vans have nothing in the rear other than the fiberglass top.

Still Moving along nicely.I would Really like having a awning. Reminded me about the one I that I bought just before a move that the ex ended up with...

It's not the best, but it will do for what I plan on using it for.

LOOKS AWESOME wish I had a motovan - always used my truck to all my race bikes!

I had a truck for years. I love a van. Once you get one, you'll always have one.

I've seen those pictures.............over @ AF1

My man. You know the struggle..lol

This a sweet project. Can't wait to see how the rest goes.

Thanks!


I started patching all the holes in the floor. I thought about welding them, but I din't wanna introduce anymore oxidation than there already was. Plus, the fiberglass resin encapsulates everything so water can't even get to it.

I ran out of resin, so the rest will have to wait a while. I have a boat job I have to go do.

Next will be fiberglass in some roof ribs that way I can mount a ceiling. Solar panels, roof vents, and the flooring.

 

[225]

Putting up insulation in the rain. The ceiling goes up the next couple of days.

Maxxfan vent is in:

Closed:

Open:

Picked up some 4WD goodies today!

 

[Firebrick43]

I cut the side off for easy removal. So they're trashed now.



I do. It's a 18" high x 4 wide area. I plan on housing the breaker panel and additional storage.



No. They had that becuase it would have passengers in the rear of the van. Since I won't, it takes up too much headroom. Plenty of vans have nothing in the rear other than the fiberglass top.




It's not the best, but it will do for what I plan on using it for.



I had a truck for years. I love a van. Once you get one, you'll always have one.



My man. You know the struggle..lol



Thanks!


I started patching all the holes in the floor. I thought about welding them, but I din't wanna introduce anymore oxidation than there already was. Plus, the fiberglass resin encapsulates everything so water can't even get to it.

I ran out of resin, so the rest will have to wait a while. I have a boat job I have to go do.

Next will be fiberglass in some roof ribs that way I can mount a ceiling. Solar panels, roof vents, and the flooring.

Um this is only true with epoxy resin, not the more common polyester resin. Not only is polyester slightly hydroscopic but is a pretty lousy adhesive. It really only sticks well to itself as its cross linking and won't even stick well to old polyester glass. I have seen many pans "fixed" by polyester resin and mat fail 5 or so years down the road. Many times peeling or popping right off.

It's hard to tell but if you did use epoxy your not supposed to with fiberglass mat. Mat has binders that keep it together and are desolved by the polyester resin. Epoxy won't desolved the binders and therefore not saturate the mat as it should.

Epoxy should be used with e glass cloth or s glass.

 

[225]

Sorry for not posting on here.

Started the 4WD conversion.

No bumper and sway bar:

Stock suspension all gone, spring hangers on:

Front axle in:

Needed to put new springs in the rear, but she's rolling:

Then made a bike trip to Deal's Gap:

All level:

Late night taco run:

 

[225]

Front bumper with Rigid Hyperspots and OBA port.

OBA system:

DIY sPOD system:

That's it for now.

 

[Bigblue&Goldie]

Killer job, looks like you could have some fun in that van!

 

[Joe Fast]

Loving this rig.


Sent from my iPad using Garage Journal

 

[metal1313]

Where did you source parts for the 4wd conversion? I've dreamed about doing something similar for a camper, all the 4wd vans around here demand stupid money

 

[225]

Killer job, looks like you could have some fun in that van!

Thanks, that the plan.

Loving this rig.

Thanks!

Where did you source parts for the 4wd conversion? I've dreamed about doing something similar for a camper, all the 4wd vans around here demand stupid money

The "kit" came from ujointoffroad.com. But I sourced my own axle and misc parts.



My axle is a 2000 f250 axle that I rebuilt.

Before:

After:

 

[225]

Before:

After:

I had a vision lolol

 

[EOC_Jason]

Super nice!

What about transfer case and all that? Or have you not hooked that part up yet?

 

[225]

Super nice!

What about transfer case and all that? Or have you not hooked that part up yet?

I haven't got that far yet. Next is the rear end. I have 3.55 gears and it suuuucks. Adding a ARB locker, 35 spline axles, and 4.10's. Then the T case and trans rebuild.

Lots of work and $$$ and can't see a difference lol.

Some people commented (not on here) about how I needed all this extra stuff to do it. The only crazy tool I have is a MIG welder. Everything else was done with basic tools. And a really nice set of pry bars and good hammers lol

 

[JustinS]

Between you and Gregor I'm going end up divorced living in a 4x4 e-series van.

 

[WILLIE*WILL]

nice

 

[SteveH-CO]

Very well done. Great photos and explanations.

 

[225]

Between you and Gregor I'm going end up divorced living in a 4x4 e-series van.

According to my wife, me too.

nice

Thanks.

Very well done. Great photos and explanations.

Thanks.

I made my first long trip in the van yesterday. I work on a boat, and it's a 12 hour drive. I usually stop and sleep in the van at some point during the drive.

Handling:

The handling of the van was great. When I made it to Atlanta (4 hours in), the ABS cable was rubbing the rotor and gave the ABS light. A zip tie fixed that, but I'll replace the cable when I get back home.

Gearing:

The van came with 3.55 gears, and with the bigger tires, it suuuuuucccks. The transmission is always hunting and stays in OD when it's not supposed to. And the revs are way higher, so are my EGT's. Gearing is top of the list.

I stopped in Louisiana, and it was still in the 30's. I have a roof vent, just not powered yet. I opened it all the way and cracked the two front windows and ran the Mr. Buddy heater all night.

Lots of in cab condensation from the propane. But no stinky fumes and my Co2 monitor didn't go off. So a success. I'll be switching to a wave 3 shortly.

Keeping me toasty:

When I get back in, gearing is first. Then maybe trans and t case.

 

[bad_idea]

Interesting project. Subscribed for updates.

 

[Firefighter1406]

This is really cool. You have done a lot of nice work. Looking forward to seeing the finished product.

 

[Posi]

Updates?

 

[Bryanthegreat]

I used to convert those vans for work back in the day. I forget when but the steel cages were mandated to comply with fmvss220 rollover standards. If you don’t brace it when you cut out the roof and door header you might wind up with door alignment issues. Looks like a Braun lift and building a remote would be simple and save you a few bucks. I believe they switch ground and that circuit is usually wired to the emergency brake. There should be a 2 pin white plug on the front that has been cut
And wired to the vehicle. They were shipped with a loop to complete the circuit you would need to make sure that is connected or the lift will not work. Or supply ground to the common side of the switches another way.

 

[Bryanthegreat]

Should have looked further looks like you are done with that already

 

[225]

Wow, 6 months since my last update. Haven't done much LOLOL... Mostly just camping.

I have a big trip planned for November, so I need to crank some stuff out very soon.

Done some camping in Gulf Shores, AL.

Deal's Gap:

Still not 4WD. I know, I know.... Honestly, I just haven't had the energy to finish it. But I'm getting there. The biggest project was the rear end gears / locker. I've rebuilt a few transmissions, and that's easy to me. I knew going into this rear diff install that I wasn't gonna like it.

Overall, it wasn't as bad as I thought. I learned a few tricks from when I installed new rear springs that helped me out a lot. My best tool was 2 ratchet straps. I used them to cinch up the shocks to install them back on the axle. And to move the axle around to line up the centering pins. It was a breeze compared to last time.

Rear axle out:

Gutted:

Air locker in with gear tooth patterns:

All new brakes / calipers / rotors. Since the install and after 4 brake bleeds, I'm still getting air in the system. I need to chase that down. It's driving me nuts.

Shortened gas tank:

Sprayed the whole van with Raptor Liner:

Drone shot:

Next up is do a balls out interior build so the wife and I have a place to sleep. We're doing a 2 week cross country trip and I need to knock a lot of stuff out asap.

 

[bad_idea]

What is that large stand thing in the last picture?

 

[225]

What is that large stand thing in the last picture?

"Art" it's a big metal fish by the river.

 

[sqznby]

Man, that is awesome.
You ever come out to the coast?

 

[Caribou_Precision]

Awesome van.

I've been toying with the idea of a 12v swap and 4wd in an older econoline. The prices on the 7.3 econolines seems as high as the 4wd pickups which was a surprise.

 

[225]

Man, that is awesome.
You ever come out to the coast?

Thanks!
Sometimes. I have friends in Wilmington and the Dirty Myrtle.

Awesome van.

I've been toying with the idea of a 12v swap and 4wd in an older econoline. The prices on the 7.3 econolines seems as high as the 4wd pickups which was a surprise.

It's crazy how much they go for. No lie, my van was $2200 on eBay. I think the mileage kept people away. It had 330k miles on it. I have 370k on it now.

I wanna do a Cummins swap. The problem is, my vans cranks every time I crank it. And has given me zero engine problems. Everything else is breaking lol. Cost of owning a 20 year old van. I've also done a bunch of small engine upgrades and known parts that fail as preventive measures.

The van is really a beast and super fun to drive. I've owned a Nissan GT-R before and I swear I can't stop to get fuel without a 30 minute conversation about my van. I literally get thumbs up from so many people just riding around. NEVER had any of that with the GT-R. When they find out it's diesel, their head explodes.