FRANKIE - '96 E350 7.3L 4x4 High Top Camper Build

swedishSTile

Observer
My wife and I have always loved camping. In July of '15 we had our first child and saw no reason why we could not continue to camp. At 6 weeks old we took her on her first camping trip and while it was a blast we realized that we were clinically insane for taking a 6 week old camping, it was way more stress than fun.. However, nature made her so unbelievably calm and contented we eagerly planned our next trip. We waited and took her again at 3 months and while it went better it was still not as relaxing as we would have liked. 6 months was better still but the trip was cut short because the weather turned cold. At 9 months we rented a tent cabin with a pot belly stove which I fed wood into every two hours ever night. Every trip had its challenges and most were cut short by at least a day. We decided that if we were going to continue to camp in the places we like to camp (off grid, zone camping, tent only campgrounds, campgrounds with difficult access etc) we were going to need to buy a camping vehicle. We looked at everything from $100K custom sportsmobiles to 4x4 Chinooks to mini class C's but never really moved on anything. Earlier this year we found out we were having a 2nd child and decided that if we were going to continue to camp we HAD TO HAVE a camping vehicle other than my 4X4 F150.

The search began in earnest and we kept returning to Sportsmobile. We went back and forth about the value it would provide our family versus the financial cost. We ultimately decided that we would never get $60-100K worth of use out of a used or new sportsmobile so I started looking for cheaper solutions. A couple of weeks ago I found a 1997 Chinook Concourse with a 7.3 powerstroke. It checked many of the boxes my wife wanted like a bathroom/shower, refrigerator and cook top as well as the boxes I wanted checked like the ability to convert to 4X4, a furnace, inside sleeping, diesel engine and short length. The vehicle was located in Texas and being in Southern California it was problematic. I bought a plane ticket and then didnt go. The lack of two separate beds (the concourse has a dinette and sofa that turn into a large king size bed) was a bit of a deal breaker for me and when combined with the hassle of going to get the vehicle I decided against going out.

On December 13th, a Tuesday my colleague sent me an add from Tucson Craigslist, it had been up for 3 hours. I called immediately and asked the seller to hold it for me, Paypal'd him a deposit and went to work on convincing my wife. What I had forgotten was that the following day, the day I planned to fly out and pick up the vehicle, was her company Christmas party. She was not happy. On top of that the vehicle was missing her must haves, a shower, a toilette and inside cooking. But my wife is amazing. She knows I worked hard for the money to buy this vehicle and she told me to go get it.

On Wednesday morning I flew out and was picked up at the airport in my soon to be new rig by Dante, his wife and his 2 year old son. The rig is a 1996 Ford E350 7.3L. It has a high top camper that was taken off of a Chevy van and modified to fit the narrower rear of the ford. The van started its life as a shuttle where it accumulated somewhere around 300K miles. Dante purchased the van 10 years ago and used it extensively, modifying it and re-configuring it to meet his needs at any given time. Early this year he popped the engine on it. His EGT sensor was mounted too far downstream and while towing he got the motor too hot, not realizing that the manifold temperatures were much higher.

His brother had a low mileage (~60K) F250 7.3L 4x4 which became the donor vehicle. From it he swapped the motor, transmission, transfer case and front axle. Before putting everything into the van he had the trans and transfer case rebuilt and beefed up to handle a tuned 7.3 and rebuilt the front axle. He swapped a rebuilt Dana 70 Dually into the rear for added stability and the upgrade to disk brakes.

A major upside to this rig for me was the year. In California, diesel vehicles that are 1997 or older are exempt from smog requirements. This means I can run a fully tuned and upgraded powerstroke without having to deal with the hassles of emissions inspections. The added bonus is also clearly the 7.3 powerstroke itself which is an enormously capable and reliable engine.

I purchased the vehicle and left Tucson at 1PM (12 california time). I hustled her across AZ and California, pulling 75+ mph (even up the grades) arriving in time to make an appearance at the Christmas party (brownie points!!!). So on to the truck...

As I bought her:
-Fully built E4OD transmission and T-case
-New front and rear driveshafts
-Fresh Dana 70 dually rear end with Posi and Mag Hytec cover (3" wider on each side = more stable)
-Fresh Dana 50 TTB front axle with custom progressive coil springs and lengthened radius arms
-Custom valved Fox 2.0 smooth body shocks all around
-Custom 45 gallon fuel tank
-UJOR trans cross member
-Transmission cooler
-Low mileage replacement engine
-Swamps tuned T/S 6 position chip
-Baby Swamps injectors
-Rebuilt fuel bowl and all fuel lines
-New 17 deg. HPOP
-RiffRaff HPX
-Rebuilt turbo with Wicked Wheel, 1.0 housing with ebpv delete
-Bellowed up-pipes
-4" turbo back exhaust
-Custom front bumper with lights and 2" hitch
-Tow mirrors
-Tow package with brake controller
-A-pillar gauges (EGT, Boost, Trans Temp)
-All new accessory pullies and tensioner
-New water pump
-New P/S pump
-New A/C compressor
-New vacuum pump
-Solar power panel, controller and battery for ARB fridge, inverter and LED lights
-ARB fridge with slide out
-TruckLite super bright LED headlights
-Rear seating converts to large bed with storage underneath
-Upper storage converts to second bed

My plans for the truck are:
Isotherm 130 DC Refrigerator
- Webasto Dual Top Evo 6 (diesel forced air and hot water heater)
-Webasto Diesel X100 Cook Top
- Reupholster van
- Swivel base for passenger captains chair
- Fresh and Grey water tanks pump and lines
- Galley sink
- Outdoor shower
- 2nd house battery and upgraded solar controller and battery isolator
- Small TV with blueray player
- Build new galley cabinet
- New Tires
- Aluminess Nerf steps

Possible upgrades if money permits
-Aluminess rear tire carrier and storage
- Dana 60 solid front axle swap to remove Dana 50 TTB

The truck is painted Subaru Desert Khaki- a kind of green-grey-olive-beige color. We have, I think fittingly, named her Frankie after Frankenstein as she is a cobbled together green monster. In the higher states of tune she will leap a couple of car lengths at highway speed in the blink of an eye, has parts from many places, is big, is loud, and is altogether Frankenstein'ish. So without further adieu......

I give you Frankie
5EDF5nil.jpg


I will upload more pictures of current interior and configuration later and will update this post as I build her out to suit our needs. We cant wait to get out and start exploring!! Thanks for looking!

Cheers,
Brian
 
Last edited:

bigskypylot

Explorer
My wife and I have always loved camping. In July of '15 we had our first child and saw no reason why we could not continue to camp. At 6 weeks old we took her on her first camping trip and while it was a blast we realized that we were clinically insane for taking a 6 week old camping, it was way more stress than fun.. However, nature made her so unbelievably calm and contented we eagerly planned our next trip. We waited and took her again at 3 months and while it went better it was still not as relaxing as we would have liked. 6 months was better still but the trip was cut short because the weather turned cold. At 9 months we rented a tent cabin with a pot belly stove which I fed wood into every two hours ever night. Every trip had its challenges and most were cut short by at least a day. We decided that if we were going to continue to camp in the places we like to camp (off grid, zone camping, tent only campgrounds, campgrounds with difficult access etc) we were going to need to buy a camping vehicle. We looked at everything from $100K custom sportsmobiles to 4x4 Chinooks to mini class C's but never really moved on anything. Earlier this year we found out we were having a 2nd child and decided that if we were going to continue to camp we HAD TO HAVE a camping vehicle other than my 4X4 F150.

The search began in earnest and we kept returning to Sportsmobile. We went back and forth about the value it would provide our family versus the financial cost. We ultimately decided that we would never get $60-100K worth of use out of a used or new sportsmobile so I started looking for cheaper solutions. A couple of weeks ago I found a 1997 Chinook Concourse with a 7.3 powerstroke. It checked many of the boxes my wife wanted like a bathroom/shower, refrigerator and cook top as well as the boxes I wanted checked like the ability to convert to 4X4, a furnace, inside sleeping, diesel engine and short length. The vehicle was located in Texas and being in Southern California it was problematic. I bought a plane ticket and then didnt go. The lack of two separate beds (the concourse has a dinette and sofa that turn into a large king size bed) was a bit of a deal breaker for me and when combined with the hassle of going to get the vehicle I decided against going out.

On December 13th, a Tuesday my colleague sent me an add from Tucson Craigslist, it had been up for 3 hours. I called immediately and asked the seller to hold it for me, Paypal'd him a deposit and went to work on convincing my wife. What I had forgotten was that the following day, the day I planned to fly out and pick up the vehicle, was her company Christmas party. She was not happy. On top of that the vehicle was missing her must haves, a shower, a toilette and inside cooking. But my wife is amazing. She knows I worked hard for the money to buy this vehicle and she told me to go get it.

On Wednesday morning I flew out and was picked up at the airport in my soon to be new rig by Dante, his wife and his 2 year old son. The rig is a 1996 Ford E350 7.3L. It has a high top camper that was taken off of a Chevy van and modified to fit the narrower rear of the ford. The van started its life as a shuttle where it accumulated somewhere around 300K miles. Dante purchased the van 10 years ago and used it extensively, modifying it and re-configuring it to meet his needs at any given time. Early this year he popped the engine on it. His EGT sensor was mounted too far downstream and while towing he got the motor too hot, not realizing that the manifold temperatures were much higher.

His brother had a low mileage (~60K) F250 7.3L 4x4 which became the donor vehicle. From it he swapped the motor, transmission, transfer case and front axle. Before putting everything into the van he had the trans and transfer case rebuilt and beefed up to handle a tuned 7.3 and rebuilt the front axle. He swapped a rebuilt Dana 70 Dually into the rear for added stability and the upgrade to disk brakes.

A major upside to this rig for me was the year. In California, diesel vehicles that are 1997 or older are exempt from smog requirements. This means I can run a fully tuned and upgraded powerstroke without having to deal with the hassles of emissions inspections. The added bonus is also clearly the 7.3 powerstroke itself which is an enormously capable and reliable engine.

I purchased the vehicle and left Tucson at 1PM (12 california time). I hustled her across AZ and California, pulling 75+ mph (even up the grades) arriving in time to make an appearance at the Christmas party (brownie points!!!). So on to the truck...

As I bought her:
-Fully built E4OD transmission and T-case
-New front and rear driveshafts
-Fresh Dana 70 dually rear end with Posi and Mag Hytec cover (3" wider on each side = more stable)
-Fresh Dana 50 TTB front axle with custom progressive coil springs and lengthened radius arms
-Custom valved Fox 2.0 smooth body shocks all around
-Custom 45 gallon fuel tank
-UJOR trans cross member
-Transmission cooler
-Low mileage replacement engine
-Swamps tuned T/S 6 position chip
-Baby Swamps injectors
-Rebuilt fuel bowl and all fuel lines
-New 17 deg. HPOP
-RiffRaff HPX
-Rebuilt turbo with Wicked Wheel, 1.0 housing with ebpv delete
-Bellowed up-pipes
-4" turbo back exhaust
-Custom front bumper with lights and 2" hitch
-Tow mirrors
-Tow package with brake controller
-A-pillar gauges (EGT, Boost, Trans Temp)
-All new accessory pullies and tensioner
-New water pump
-New P/S pump
-New A/C compressor
-New vacuum pump
-Solar power panel, controller and battery for ARB fridge, inverter and LED lights
-ARB fridge with slide out
-TruckLite super bright LED headlights
-Rear seating converts to large bed with storage underneath
-Upper storage converts to second bed

My plans for the truck are:
Isotherm 130 DC Refrigerator
- Webasto Dual Top Evo 6 (diesel forced air and hot water heater)
-Webasto Diesel X100 Cook Top
- Reupholster van
- Swivel base for passenger captains chair
- Fresh and Grey water tanks pump and lines
- Galley sink
- Outdoor shower
- 2nd house battery and upgraded solar controller and battery isolator
- Small TV with blueray player
- Build new galley cabinet
- New Tires
- Aluminess Nerf steps

Possible upgrades if money permits
-Aluminess rear tire carrier and storage
- Dana 60 solid front axle swap to remove Dana 50 TTB

The truck is painted Subaru Desert Khaki- a kind of green-grey-olive-beige color. We have, I think fittingly, named her Frankie after Frankenstein as she is a cobbled together green monster. In the higher states of tune she will leap a couple of car lengths at highway speed in the blink of an eye, has parts from many places, is big, is loud, and is altogether Frankenstein'ish. So without further adieu......

I give you Frankie


I will upload more pictures of current interior and configuration later and will update this post as I build her out to suit our needs. We cant wait to get out and start exploring!! Thanks for looking!

Cheers,
Brian

Very nice. Looks like a great platform to get off the grid with. Looking forward to seeing your mods come tomfruition!
 

gtbensley

Explorer
Awesome! I saw this posted on CL and wondered if someone on here would buy it, seemed like a heck of a deal. Looking forward to more pictures and your travels.
 

swedishSTile

Observer
The night after I brought the truck home it rained. And rained and rained. We received 2". Well, some of the caulking around the interface to the camper shell had cracked and the factory sealant where the gutter is seamed 3/4 of the way back along the roof of the van had dried up. So I got a lot of water inside. Ooops. I spent a couple of hours over the weekend cleaning the inside out, washing all the cushion covers and re-sealing the entire truck. Some items are moving further down my list to make way for some replacement parts at the top. I am going to install new door seals all the way around, re-insulate the dog box and replace the seal around it. In addition to new tires I think new wheels are in order.

Does anyone have a good recommendation for a strong, cheap 16 x 8 steel wheel or alloy wheel? 8x6.5" lug with around a 4" backspace (for ford old body style hubs)

Some more pictures...
zHojQBDl.jpg
l37ZYdGl.jpg

Xb1eoGWl.jpg
PKvP4DDl.jpg
 

swedishSTile

Observer
Awesome start to a super cool rig :ylsmoke:

Thanks just a bunch of minor problems giving me headaches at the moment but once they are sorted it should get under way! Good luck with your camper company, looks like some cool concepts and fun projects.
 

IdaSHO

IDACAMPER
Thanks just a bunch of minor problems giving me headaches at the moment but once they are sorted it should get under way! Good luck with your camper company, looks like some cool concepts and fun projects.

Thanks!

Your van looks like a very fun project!

Be sure to shoot me a PM or email if you have any questions/concerns/troubles with your rig. Always willing to help the process along.
 

swedishSTile

Observer
Finally got some time to work on the van.

Re sealed the entire top and all the windows. One window is still leaking a bit. I think the frame is split and the water that makes its way into the track leaks down before it makes its way out of the weep holes. Not sure how I am going to fix this.

I welded up a frame to mount my thule bikes racks to and stuck it on the front hitch and added a locking hitch pin. Its just a U shape welded to a receiver extender. Also added a hitch basket to the back. I am probably going to fabricate a rise for the basket so it does not decrease my already horrible departure angle. Bikes and front rack can be put in the van in a pinch if I am trying to get somewhere I shouldnt.
Do2pks8l.jpg

Tgcac6Tl.jpg

qRQJxT5l.jpg

l also finally got to fabbing a support for one of the car seats. I built it out of 1X1X.120" wall square tubing. One leg is bolted through the floor to the frame of the van and the other is bolted through the floor and a spreader bar (piece of 2" x 3/16 C channel that is 12" long). It is all secured with 7/16" graded hardware which passes through the tubing and is welded to the tubing.

Everything is designed for a 150lb seat+child combo and 50g of acceleration (basically it will stay together with up to 6000lbs of force applied. It will deform slightly at that load, less than 1/4" deflection, but will not break). 50g is generally considered to be fatal. So if the seat ever does come out, everyone in the van will already be dead.

The red ratchet strap was just for test fit. I will be putting in a strap equal to the frame. The strap snugs the seat against the plywood which rests on the frame. The car seats tether strap will be hooked to a flush mount d-ring in the floor.

FEA analysis: Bolted connections, 3000lb vertical load, 3000lb side load.
cPGW8Yql.jpg


RrI7IWOl.jpg

x6vtTL0l.jpg
 
Last edited:

swedishSTile

Observer
HA! There is being morbid and there is being a realist. I consider myself the latter...most of the time. When my wife asked if it will break in an accident she was not thrilled with my answer.
 

swedishSTile

Observer
Does anyone know where to source a sway bar like this? The rig pictured is a 4x4 van ambulance. The sway bar on my van has long drop links that put the bar and end links way down in harms ways. It was originally off the van but with the high camper top its somewhat of a necessity.

9votF7sh.jpg


Got to the table last night. Decided to just move the leg to someplace slightly less than ideal rather than notch and gusset the frame. Much better idea, I dont know what I was thinking. I still need to remove the velcro for the cushion and put it on the other side of the seat back/table/bed base and make a strap for the cushion to go over the top so the velcro is not on the table top. I am also going to finish the table top so it is easier to clean and play games on.

kxaVo2dh.jpg

jpGkCCgh.jpg
 

swedishSTile

Observer
New shoes. Black Rock 997's in 16x8 shod in 305/70r16 Hankook Dynapro ATM RF10's. They were a bargain at $1600 out the door for five including road hazard certificates. I love Americas tire. It was between the hankooks and the Falken Wildpeaks. I have the wildpeaks on my truck and am very happy with them but figured I would change it up again and grab the hankooks. Just need some fender flares now. The backs sit pretty wide on the dually axle. I considered doing a different offset wheel in the rear or all the way around and then spacing the front back out but i didnt want to deal different front/rear or the spacers so it is what it is.

Q6EqFhUh.jpg

DJ56GqCh.jpg

8Ip2jBrh.jpg
 

Forum statistics

Threads
186,114
Messages
2,882,164
Members
225,874
Latest member
Mitch Bears
Top