7.3L Powerstroke Motovan Project.

[225]

Next week makes 1 year I've had my van. This is my second van. My first one was a 1999 Ford E-350, cargo, standard length 7.3L Powerstroke.

Due to life, I had to sell it. Here she is:

4 years later, eBay got me this for a song. 350k miles and in ok shape.

It was in Indiana, I live in NC. Stopped to drink some whiskey in Louisville:

Continued....

 

[225]

Gonna paraphrase the mods of the last year to get to present time.

Toyota Sienna seats:

Turbo rebuild with wicked Wheel 2 and plenum boots:

New floor, fiberglass speaker pods, LED light bar light, and cabinet. Also airline track.

Diamond Eye 4" exhaust, and tune:

 

[225]

Picked up a wheelchair lift that will be modified for a motorcycle:

The problem is, it didn't come with the remote control, but the pump works when done manually.

I bought this height top, rear doors and all interior trim. I'm out of town right now, but when I get back, it will be ready for pickup.

 

[mv213]

I’ll be watching this one. How much did you have to pay for that high-roof body?

 

[225]

I’ll be watching this one. How much did you have to pay for that high-roof body?

$650 for the top, both rear doors, and all the rear interior plastic panels.

They’re cutting the top off 6” below the original roof line. I’ll have to separate the top from the original roof myself.

Hopefully within the month I’ll also find a good front axle for the 4WD conversion.

 

[zkdiesel]

Just sold a Grumman tool truck to a guy for same reason. He was extremely stocked about the full-size alluminum liftgate and ac unit on it
Good luck,

 

[rustyjames]

You might find a remote control for that lift on eBay. Is it a Braun or Ricon?

 

[mv213]

$650 for the top, both rear doors, and all the rear interior plastic panels.

They’re cutting the top off 6” below the original roof line. I’ll have to separate the top from the original roof myself.

Hopefully within the month I’ll also find a good front axle for the 4WD conversion.

Wow, that’s a good deal. Sounds like a great project.

 

[225]

Just sold a Grumman tool truck to a guy for same reason. He was extremely stocked about the full-size alluminum liftgate and ac unit on it
Good luck,

Thanks. Mine will get a window unit in the back window, but you won't see it when the rear rack that holds the tire and generator box is on.

Wow, that’s a good deal. Sounds like a great project.

Thanks. I'm trying.

You might find a remote control for that lift on eBay. Is it a Braun or Ricon?

Braun. The cheapest remote I could find was $220. I'm building my own for $30.

The service manual says it uses 5 wires, and 2 rocker switches:

I ordered 2 momentary (on - off - on) rocker switches for $9 a piece.

XLR 5 pin cable and XLR 5 pin female plug.

This will go on the lift:

Cable for the switch box that will be removable:

Gonna put it in a shallow 1 gang box with a blank face plate and cut the holes for the switches. I'm waiting on everything to come in the mail now.

First I have to get the top on, then the lift in. But I'll have it ready to go soon.

 

[225]

The ultimate goal here, will be a 4WD van, that I can put the transfer case in neutral and pull behind a school bus that I will convert to a RV.

Van first, bus maybe next year or two.

 

[Growlertdi]

much potential here..

 

[rustyjames]

Thanks. Mine will get a window unit in the back window, but you won't see it when the rear rack that holds the tire and generator box is on.



Thanks. I'm trying.



Braun. The cheapest remote I could find was $220. I'm building my own for $30.

The service manual says it uses 5 wires, and 2 rocker switches:

I ordered 2 momentary (on - off - on) rocker switches for $9 a piece.

XLR 5 pin cable and XLR 5 pin female plug.

This will go on the lift:

Cable for the switch box that will be removable:

Gonna put it in a shallow 1 gang box with a blank face plate and cut the holes for the switches. I'm waiting on everything to come in the mail now.

First I have to get the top on, then the lift in. But I'll have it ready to go soon.

These work surprisingly well if you want to lose the cord: https://www.ebay.com/itm/12V-4CH-Ch...934849?hash=item1c69f7d8c1:g:hUoAAOSwnVVZmpvh

 

[225]

These work surprisingly well if you want to lose the cord: https://www.ebay.com/itm/12V-4CH-Ch...934849?hash=item1c69f7d8c1:g:hUoAAOSwnVVZmpvh

Holy **** that's cool. I ordered one.



I'm gonna try it for sure. It says it needs 12v to power it up, and I can use the power from the dome light, since the door will be open to use.

Worst case, I'm out $12 if it doesn't work.

 

[rustyjames]

Holy **** that's cool. I ordered one.



I'm gonna try it for sure. It says it needs 12v to power it up, and I can use the power from the dome light, since the door will be open to use.

Worst case, I'm out $12 if it doesn't work.

I built a couple of them for my wheelchair lifts, it's amazing the range they have. Do yourself a favor and buy a bigger plastic workbox because there's no room in the one that it comes with. You should also use an on/off switch and circuit protection.

 

[theoldwizard1]

My '98 E150 is being consumed by rust. Sad to see it go.

 

[RedBKM]

I'm not up on vans...

How do those extended tops attach? Why not buy the whole body?

 

[225]

My '98 E150 is being consumed by rust. Sad to see it go.

Sorry to hear that.

I'm not up on vans...

How do those extended tops attach? Why not buy the whole body?

A body swap isn't that easy. This is. The top is attached with screws and seam sealer.

I'll run a wire between the fiberglass and old roof top and cut the seam sealer. Clean the top. Cut a hole in my roof, and put the top on mine. Only takes half a day or less.

 

[gnpenning]

Sorry to hear that.



A body swap isn't that easy. This is. The top is attached with screws and seam sealer.

I'll run a wire between the fiberglass and old roof top and cut the seam sealer. Clean the top. Cut a hole in my roof, and put the top on mine. Only takes half a day or less.

I'm curious, are you using a straight seam sealer or a panel adhesive/seam sealer?

Do you have to brace the sides when you cut out the top or is the structure integrity such that it will not move?

Or can you put the new top on then cut out the opening??

What a great project. I really like adventure type vehicles.

Keep this updated.

 

[225]

I'm curious, are you using a straight seam sealer or a panel adhesive/seam sealer?

Do you have to brace the sides when you cut out the top or is the structure integrity such that it will not move?

Or can you put the new top on then cut out the opening??

What a great project. I really like adventure type vehicles.

Keep this updated.

No bracing is needed. The van bodies are essentially a tin can. They're pretty flimsy to begin with. The fiberglass top has a lot of structural integrity. I'll just measure the opening and cut the hole to match. The part over the driver area stays intact even though the top will cover it. The hole starts right behind the front seats.

I'll be using screws and urethane adhesive by 3M, and screws.

Here's a video of a top install:

 

[225]

I was headed home from work, and a car crossed the double yellow into my lane and almost hit me. I swerved out the way, and hit the curbing. 2 flat tires at once. Yay me.

Drove my wife's car 800 miles on a Uhaul trailer, didn't even know it was back there.

Picked up the high top.

It came with a metal cage. Never seen that before, but I think it's cool.

Inside and out. Gonna have a busy week.

 

[225]

I cut off all the tabs, sanded, primed, and painted the ribs to prevent future rust:

Gutted the interior enough to get the top on. Once I have no roof and I can stand up and work, I'll finish the rest.

Forgot to add that I bought 2008+ headlight bezels. I'm putting the 08+ front end on next. I should have the top on tomorrow.

 

[225]

Thinking about cutting my wrists right about now:

Got the hard part fitted. Still need to do some cleanup welding, but everything fits, which was a huge relief.

Talk about a sunroof:

The top is just sitting on the van. Still needs to be bolted down, but I'm over the hump:

A little motorcycle livery. the rear doors are getting bedliner tomorrow. Just prepping it, and put the windows in for full effect.

 

[Strouty]

That is a lot of work! Looks like you are in good shape now that the back doors have been modified.

 

[gnpenning]

Moving right along. What did you end up using to cut off the top?

Are you planning on selling the old doors to help recoup some cost?

 

[225]

That is a lot of work! Looks like you are in good shape now that the back doors have been modified.

The worst part is over. It was quite scary for a little while there.

Moving right along. What did you end up using to cut off the top?

Are you planning on selling the old doors to help recoup some cost?

Tools of choice. The grinder had a cut off wheel.

The rear doors are going on Craigslist. And anything else I don't use.



I have an 8ft. awning coming in the mail. Once the top gets the bedliner treatment, it will get a vent fan and solar panels.

 

[225]

Whew, it's been a busy last few days. I'm pretty excited at the progress.

Installed a 8ft awning.

Sanded, primed, and sprayed bedliner:

Installed the wheelchair lift that will be extended to a motorcycle lift.

Using a 4 channel wireless relay, I made the remote wireless. And it only cost me $20.

Shoutout to member rustyjames for the idea and wiring info.

 

[rustyjames]

Excellent progress, indeed. Note to others who might want to build a lift like 225's, the best ones to work with are the older Braun lifts without circuit boards. They're easier to wire up, more reliable and easy to repair.

 

[225]

Excellent progress, indeed. Note to others who might want to build a lift like 225's, the best ones to work with are the older Braun lifts without circuit boards. They're easier to wire up, more reliable and easy to repair.

Thanks again. Mine didn't have a circuit board.

Just so happens that the cylinder that lifts up the flap on the ramp blew the seal. I capped the line, since the flap is going away anyway.

 

[225]

Tested out the $120 eBay awning ARB knockoff. My thoughts? It's worth what I paid. Not a penny more.

I ordered all new locks because I had 2 different keys I had to use.

The old locks.

I knocked off the flip down flap and planning for the flip out extension.

I trimmed the driver side interior panel to clear the rear A/C. I guess I need to figure out how to cover that up, but it's on. I also put in the the passenger side too. These came with the high top.

Before I start working on the ceiling, I need to install solar panels, and a roof vent. But before I can do that, I'm going to spray bedliner the entire van.

I may do the flooring next. We'll see.

 

[AZ Pete]

too cool! subscribed


Sent from my iPad using Tapatalk

 

[shedfullatools]

This is awesome Especially like seeing the high top being installed, was always curious how those were done as far as reinforcements and what not. Side note would you be able to post a link to the awning you bought? I've been trying to get one but cant find anything under $200 that is even remotely close to what I want.

 

[225]

too cool! subscribed

Thanks!

This is awesome Especially like seeing the high top being installed, was always curious how those were done as far as reinforcements and what not. Side note would you be able to post a link to the awning you bought? I've been trying to get one but cant find anything under $200 that is even remotely close to what I want.

$123.90. I can make a video if you want of it. But if you look on the YouTubes for eBay awning, it's the same one.

Link: https://www.ebay.com/itm/Awning-Roo...var=492275539763&_trksid=p2060353.m2749.l2649

Video:

 

[theoldwizard1]

Tools of choice. The grinder had a cut off wheel.

I saw a video where a body man replaced his air saw with a M12 Fuel Hackzall like above. Only complaint was the battery did not last all day.

He bought standard reciprocating metal blade and stacked them up, 10 at a time and placed them in a vise. Using one M12 blade as a guide, he ground the attachment end to match ! Much cheaper than buying the M12 blades.

 

[theoldwizard1]

I ordered all new locks because I had 2 different keys I had to use.

The old locks.

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.

 

[Stuart in MN]

Neat project!

The part over the driver area stays intact even though the top will cover it. The hole starts right behind the front seats.

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

 

[EOC_Jason]

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

 

[gnpenning]

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...

 

[xin]

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

 

[Worsedog]

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

 

[kazlx]

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