E-350 Cutaway with Total Composites Box

[CalgaryMcLean]

Any flexing pics with just the subframe?
What steps are you using?

I day dream about a similar (E-series with composite box) rig all the time so subscribed for more pics, details, and updates, great work so far!

No pics of the flex with the subframe installed.
Will do more testing after the camper box is installed.

The steps are Lippert Kwikee 25 Series Electric 3-step.
I looked at and modelled a LOT of different steps and these were the ones that fit the best.
Collapsed, they fit into their space without hanging below the toolboxes, and the rise between steps matches the final step of the camper stairwell.

 

[CalgaryMcLean]

Pronghorn EV working away, assembling the camper box.

Floor panel with cut-outs for the door and the fenders:



Fitting the pultrusions:



The plan for the front wall:


How it worked out:



It is coming together!

 

[CalgaryMcLean]

Skid plates for the engine, transmission, transfer case and fuel tank.
Also some theft deterrent for the cat converter.
All designed and fabricated by 1251 Innovations.






The design and fabrication: https://www.instagram.com/reel/Cn--auhDgqI/?utm_source=ig_web_copy_link

Installation: https://www.instagram.com/reel/Cn-kIjujOYG/?utm_source=ig_web_copy_link

 

[REF]

Awesome! Thanks for sharing, following with interest. Those guys are doing a great job, nice work!


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[CalgaryMcLean]

A couple more pictures as the camper box assembly continues.

 

[trackhead]

Looks great!

 

[shortbus4x4]

Looking good.

 

[CalgaryMcLean]

A door, a hatch and side windows. It's coming along.
Roof, rear wall and rear boxes coming soon!



And more pics from PronghornEV

 

[Ninelitetrip]

Great looking build.

How did you decide on the overall length of the van, and the interior dimensions of the habitat? Is Pronghorn doing the interior fit-out?

Great work on the underbody pieces, good idea for the cat.

E-350 7.3 "Economy vs. F series 7.3 "Premium" engine. Is anything planned to get some extra HP, say a 5 Star tune?

 

[CalgaryMcLean]

Great looking build.

How did you decide on the overall length of the van, and the interior dimensions of the habitat? Is Pronghorn doing the interior fit-out?

The interior dimensions are 122" long x 80.5" wide x 80.5" high.

The length is about as short as I could go with this chassis. If the camper was longer, then the camper box or spare tire or rear storage boxes would start to reduce the departure angle, and I wanted the camper square at the rear, not angled.

With an angled rear on the camper, then the spare tire and storage boxes have to mount higher, which is not a plus.

Any shorter, and then the fuel tank hanging down becomes the limiting factor. This length also gives me just enough frame rail behind the fuel tank to mount the rear camper supports and rear bumper.

The width is enough to let me have an elevating bed, running east-west, and still clear the window frames.

I will be doing the interior myself.

The engine is the standard economy tune for the E-350. Coming from a VW Westfalia Syncro background, the standard tune should be more than enough power for my needs.

 

[CalgaryMcLean]

Pronghorn EV continuing with the assembly.

Back wall with storage boxes installed.
Spare tire mounts between the boxes.





Side view with the entry door installed.


Roof, roof fan, clearance lights, corner caps, door grab handle, and lots of caulking still to go.
A few more weeks and then I will start on the interior.

 

[REF]

Looking great, without digging too far into TC options, I’m curious if you know if they offer a cab over version that’ll fit on the cutaway.


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[1000arms]

Looking great, without digging too far into TC options, I’m curious if you know if they offer a cab over version that’ll fit on the cutaway.

@Victorian

 

[Victorian]

Looking great, without digging too far into TC options, I’m curious if you know if they offer a cab over version that’ll fit on the cutaway.


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You could order a custom box through any of our builders. Feel free to reach out. Cheers

 

[CalgaryMcLean]

Pass through framed with aluminum channel. Dry fit for now, and off to powder coating.


Stair well finished and trimmed.


Roof assembly with front clearance lights and fan installed:


Rear clearance lights. These are all dual intensity. The outers will also be signal lights. The inners will also be brake lights.