cowboy 4x4 ford van

[cowboy4x4]

So when I'm driving I keep hearing a squeak when I go over any kind of bump. I finally pinpoint the sound, its coming from the left rear leaf spring. It seems there are some type of plastic spacers in between the leafs and mine are coming out hence the squeak. So a trip to IKEA nets me a bread board made of thin polyethylene. Cut it into strips and now waiting to take the leafs apart and install in between.
you can see here the piece that is falling out.

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[the boogie van]

sorry, but those probably won't stay in there for long. the factory sliders have plastic nubs that fit into holes on the springs.

nice work on the insulation, its such a ***** but worth it the first time you drive a non-tin can

 

[cowboy4x4]

Started on some upholstery work. I have to use the van for work and play, the slide out box is strictly for off road stuff. So I figured out a color scheme for the interior, the factory front is gray and I like that. I like the fact that it is more or less a neutral color and is easy to keep clean, so gray and black will be the colors. I repainted the front of the slide out box texture black and glued down some gray indoor/outdoor carpet. I'm not going to be using carpet on the floors anywhere as it is just a pain to keep clean and doing double duty just wouldn't work for me. It already has 3/4" plywood on the floor so for now I think I will just paint it with a dark gray oil based paint. At a later date once the floor plan is done I'm going to look for a type of rubber flooring that was in my fifth wheel, it was gray and had round flat top circle/bumps on it and was very durable, you could drive on it. I decided to make my own back door panels as well and will cover them with the same gray carpet.

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[cowboy4x4]

So my van is an E350 which is 1 ton and I saw another E350 1 ton and the rear axles are different. This other guys van axle sticks out throught the rim just like my Ford Dually did, where as my 1 ton van it does not its flush with the rim. Now I'm also hearing things about a "sterling" rear end. I'm wondering if I should keep my rear end (which would be cost effective in the 4x4 swap) or should I get a different rear end.

 

[nely]

A non-floating 1 ton rearend? Never heard of it. Any pics?

So my van is an E350 which is 1 ton and I saw another E350 1 ton and the rear axles are different. This other guys van axle sticks out throught the rim just like my Ford Dually did, where as my 1 ton van it does not its flush with the rim. Now I'm also hearing things about a "sterling" rear end. I'm wondering if I should keep my rear end (which would be cost effective in the 4x4 swap) or should I get a different rear end.

Sent from my SGH-T959 using Tapatalk

 

[ujoint]

You have the semi float Dana 60. As long as you don't go over 35's or plan to wheel the van hard with a locker, it will do just fine.

Some guys upgrade to the Sterling because they plan to tow heavy loads, or they run large tires, or they just don't like the semi float axle.

 

[Toolman]

If you have time and some extra cash I have found Sterling axles around here for $550 to $700. I'm planning doing the upgrade on the side when time and money permits. You need to move the spring perches and shock mounts to line up with the frame. For now I'm using the stock 60 and adding an ARB, which will be used in a buggy later on or I'll sell it.

The flooring you speak of is Lonseal (LONCOIN 2) it is very costly at over $1000 for the entire floor on the van, I found some imitators however they don't look or react the same. In my build thread you'll see the stuff I'm using it cost me $270 shipped to my door for a 9' X 21' piece. I have some samples of their coin design and their diamond plate pattern, the color didn't match and it was to thick for my application. I bought the black Levant pattern for ease of making the seams line up, and I'll be using the left overs to line the interior of the door storage and an entry way floor mat iI can throw on the ground when camping.

http://www.floorsurfaces.com/fsi-blt.html

Nice work on the van cowboy keep it up, we'll be meeting up on trail in no time. :smiley_drive:

 

[cowboy4x4]

so I came across some cool rubber rollers 2 3/8 OD w/ a 1/2 hole all the way through the center and they are 12" long. I plan on making roof rack and I will install these across the back of it so when I put the kayaks up there they can roll up instead of grinding on the back rail.

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[cowboy4x4]

I kept my muffler from my diesel truck I had awhile back and put it to good use. It's an RBP stainless steel muffler, the V10 has a little deeper rumble now.

 

[cowboy4x4]

So here is a teaser shot of the rock/rub rails w/bump out I'm making. The bottom will be 2x2 square tube and the back bump out tube will be 1.75 and the front tube will be 1.5. This shot gives you the general idea of the design, the 1.5 will be notched to fit snugly onto the 1.75. I'll update as I go.

 

[Toolman]

Can't wait to see them on.

 

[CodyY]

Thanks for the info on the FortiFlash.

looking good.

 

[cowboy4x4]

All I have to do is add the struts between the long tube and the square tube.

 

[cowboy4x4]

Hard to get a full size close up shot, these things are 8' long. Will paint and mount over the weekend.

 

[Toolman]

I like it