ExploringNH's 2000 Ford Excursion build
- Thread starter ExploringNH
- Start date
Like the build and the direction your going with this!
I have a 04 X and now have truck lust. Have you had any drive line issues with the lift and tires your running?
I'm thinking if you cut the wheel wells and flatten out the bed area it will make life much easier to fit a bed sideways and or arrange for under bed storage like rolling draws. Cutting the wells don't look like it will hamper wheel travel and if it does you having a hell of a time anyway!
I have a 04 X and now have truck lust. Have you had any drive line issues with the lift and tires your running?
I'm thinking if you cut the wheel wells and flatten out the bed area it will make life much easier to fit a bed sideways and or arrange for under bed storage like rolling draws. Cutting the wells don't look like it will hamper wheel travel and if it does you having a hell of a time anyway!
ExploringNH
Explorer
I've been trying hard to figure out a best use of space for the mattress, gear, and a usable, quick deploying kitchen. It seems that no matter what I do, I end up with some dead storage space that can't be accessed without pulling up the mattress. I am thinking of using this space for a water tank on one side and I'm still not sure about the other side.
The drawing below is a quick, somewhat to scale but not really, mockup of what I've come up with for a layout so far. Not terrible, but not great either.
The downside of this setup is that it really is functionally no different than what I have now. It is nicer and cleaner, but that is it. I still have no seating in the back of the truck for working on the computer or eating and I still have no place to cook inside the truck. I am coming to terms that it just won't happen. I could do a folding bed setup but none that I have seen are as comfortable as a real mattress, plus they would add time to deploy and take up storage space underneath. It is all a bunch of compromises.
My stove would be hard mounted at the very front of one of the drawers so that it is just a matter of pulling it out and starting to cook. All of the cabinets would have doors on them, I just didn't draw them. Fridge would be at the very front, right where I have it currently. I like to access it while driving. The drawer up front would pull out of the rear side doors of the truck. In this layout the passenger rear door is pretty much useless since it is blocked by the platform. The driver's rear door is the one I use most right now anyway so I sort of planned it for that.
If I use this design and use a folding bed, with some type of hinge like a rock and roll, then I get most everything I want. I can have a pull out table in the cabinet side as well as a place to put the stove on rainy nights if necessary. I would lose the left hand big storage drawer to make room for a walking path but I don't need that much storage anyway.
No driveline issues at all with a 6". The Super Duty trucks can have a two piece driveshaft that can cause issues but the Ex has a single piece rear shaft and can handle big lifts without a problem.
I've certainly give some thought to trimming out the wheelwells a little bit. As you said, my tires don't come close to hitting the inside of them. The problem with width is that I am still too short above the wheelwells, so I would need to trim back some of the internal sheetmetal/bracing. I don't think I want to get that deep into this but plans could change.
Absolutely! The driver's side rear is most likely going to go with a storage box taking it's place. You can't really see out of it while driving anyway and externally accessed storage would be nice. The windows attach in such a way that it makes bolting in a storage box pretty easy. It isn't at the top of my priority list but I definitely have the idea mocked up in my head if it comes down to it and I happen to be near a welder and some sheet metal.
The drawing below is a quick, somewhat to scale but not really, mockup of what I've come up with for a layout so far. Not terrible, but not great either.
The downside of this setup is that it really is functionally no different than what I have now. It is nicer and cleaner, but that is it. I still have no seating in the back of the truck for working on the computer or eating and I still have no place to cook inside the truck. I am coming to terms that it just won't happen. I could do a folding bed setup but none that I have seen are as comfortable as a real mattress, plus they would add time to deploy and take up storage space underneath. It is all a bunch of compromises.
My stove would be hard mounted at the very front of one of the drawers so that it is just a matter of pulling it out and starting to cook. All of the cabinets would have doors on them, I just didn't draw them. Fridge would be at the very front, right where I have it currently. I like to access it while driving. The drawer up front would pull out of the rear side doors of the truck. In this layout the passenger rear door is pretty much useless since it is blocked by the platform. The driver's rear door is the one I use most right now anyway so I sort of planned it for that.
If I use this design and use a folding bed, with some type of hinge like a rock and roll, then I get most everything I want. I can have a pull out table in the cabinet side as well as a place to put the stove on rainy nights if necessary. I would lose the left hand big storage drawer to make room for a walking path but I don't need that much storage anyway.
No driveline issues at all with a 6". The Super Duty trucks can have a two piece driveshaft that can cause issues but the Ex has a single piece rear shaft and can handle big lifts without a problem.
I've certainly give some thought to trimming out the wheelwells a little bit. As you said, my tires don't come close to hitting the inside of them. The problem with width is that I am still too short above the wheelwells, so I would need to trim back some of the internal sheetmetal/bracing. I don't think I want to get that deep into this but plans could change.
Absolutely! The driver's side rear is most likely going to go with a storage box taking it's place. You can't really see out of it while driving anyway and externally accessed storage would be nice. The windows attach in such a way that it makes bolting in a storage box pretty easy. It isn't at the top of my priority list but I definitely have the idea mocked up in my head if it comes down to it and I happen to be near a welder and some sheet metal.
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gohuge
Observer
We think alike, lol. Talked to a guy who builds custom service rigs for the oil patch up here. Showed him what I want, said it would be no problem. I am going to have him fab it this Summer.
As you said, not a priority, but definitely want to do it. I'm thinking recovery gear storage/trail work tools. Strap, snatch-block, chainsaw, axe, handsaw, roadside safety stuff, etc. Lift ram assist single door, with twist handle to lock.
Door up to keep the rain off my head....lol. Gloss black powder coat.
Love the build and I have been a long time watcher of your build. I was just thinking about your space issues in the Ex. I have a 03 and have been spending more time using it to haul the trailer and family. Space for sleep platforms will be no existent for my situation but I have talked to the guy who runs Colorado Camper Van. He built this Ex with the roof top pop up. Not sure it gives you any ideas but I liked the concept.
ExploringNH
Explorer
Pretty much my same plans. I wanted a sealed box on the outside to keep dirty stuff like a wet tow strap. Often times after a recovery I end up with a dirty and wet strap on my rear floor. It would be nice to have it go in a box that could get dirty and not affect my living area.
I've seen that CCV pop-top Excursion before. That is the same size and general idea that I have in mind. I don't realy like the look of the hinges/lift mechanism but it is hard to tell from photos. I also don't like the shape and wood construction of the actual top. It sticks up too much for me and I don't like the profile of it. Small details that could probably be changed to suit personal tastes. I am curious as to why he went with that setup instead of using a fiberglass roof top from a van. I am curious to know if the profiles of the roof are too different. It sounds like I am being extremely negative of his build, but these are pretty minor and personal details. I admire the work and engineering that went into it, and the ability to actually make it a reality instead of a post on a forum.
I really like the GTRV tops. Super low profile:
A hinged top would be much easier to build but I like the space that a full pop-top offers.
gohuge
Observer
With all the trees I'm around, it would have to be low pro for sure. Wonder why he bumps the rear up so much in the back? I think it could be done, and use a rack around the out side to help support pop-up, mount awning and lights to, and
protect the front/leading edge of top from low branches. Hmm? what if you built it to the actual rack and used a "Boot" to interface between the roof and the pop-up. Maybe even inflatable like those on slide-in campers.. Maybe use
a Nice sized removable sunroof for roof penetration when not on top?
protect the front/leading edge of top from low branches. Hmm? what if you built it to the actual rack and used a "Boot" to interface between the roof and the pop-up. Maybe even inflatable like those on slide-in campers.. Maybe use
a Nice sized removable sunroof for roof penetration when not on top?
Pretty much my same plans. I wanted a sealed box on the outside to keep dirty stuff like a wet tow strap. Often times after a recovery I end up with a dirty and wet strap on my rear floor. It would be nice to have it go in a box that could get dirty and not affect my living area.
I've seen that CCV pop-top Excursion before. That is the same size and general idea that I have in mind. I don't realy like the look of the hinges/lift mechanism but it is hard to tell from photos. I also don't like the shape and wood construction of the actual top. It sticks up too much for me and I don't like the profile of it. Small details that could probably be changed to suit personal tastes. I am curious as to why he went with that setup instead of using a fiberglass roof top from a van. I am curious to know if the profiles of the roof are too different. It sounds like I am being extremely negative of his build, but these are pretty minor and personal details. I admire the work and engineering that went into it, and the ability to actually make it a reality instead of a post on a forum.
I really like the GTRV tops. Super low profile:
A hinged top would be much easier to build but I like the space that a full pop-top offers.
I like the low profiles as well. When I discussed Derek the potential of doing the mod for my Excursion, he mentioned that this particular Excursion was a one off custom. It needed the beef to handle the weight of the bikes and other things. When working with the excursion there isn't a mass produced cap to modify or use for the top. Roof profile is different than a van. Conversion vans have many options to use since adding a modified cap is common. I can't remember if it was the hinge that limited how low profile he could go. Bottom line is that there needs to be a market with enough people with Excursions who want to rip up their tops to add the pop-up. I haven't seen one particular Excursion here in about two years. But it was the one that the owner added a Land Rover Discovery roof to the back roof section and that was the pop-up. I wonder if Ursa Minor would do a custom for the Excusion?
ExploringNH
Explorer
Thanks for the response. I know there is a reason for everything and I'm glad the build worked out to suit your needs.
It is such a limited market for excursions that it doesn't make sense for anyone to mass produce something. Vans, transits, and even Honda elements have a much bigger market share.
I've never seen photos of the finished discovery pop top. Do you know if it was ever completed? Yours and his are the only ones I've ever seen with a lifting roof. I guess that shows just how small the market is.
I did some serious research and engineering yesterday and I am pretty set on moving forward with the idea. Hopefully I can complete the job. There are certainly a few big things to figure out along the way.
Sorry if I may have made it seem that the black Ex was mine. It isn't. I was just doing the research on my build out when I called CCV to discuss the possibility of having my 03 done. My 03 is more for pulling the trailer while hauling the kids and dogs. I have spent last years budget bulletproofing the Diesel engine. My New Years resolution will be working on the suspension with new springs, shocks and sway bars.
I know that CCV helped the Disco Excursion guy finish the soft side but I have never seen the final. I did see early in the build at a local REI and exchanged some emails but I should really see if he is still around to get an update.
Merry Christmas everyone.
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ExploringNH
Explorer
I don't know what happened, but this ended up in my yard last week.
It is what I wanted. Panel sides, swing out side door, and the right wheelbase. I know Ford is the common choice around here for a van conversion, but I think the AWD Express van platform might be enough. In the end, the Excursion stays though. The van really doesn't offer me enough to make up for the downsides of abandoning the Excursion. I would still want a pop-top on the van and if I am going to do that, it would be better to do it on the already built and mechanically sound Excursion.
I didn't plan on doing the roof this year, but one thing led to another and now I have no headliner. So, the roof rack had to come off next. I'll have to find a way to remount the light bar. Some parts ordered, some brackets made. Friday I start work on making a template of the roof and mockup the new pop-top roof. Interior build is on hold until the new roof is in.
I will definitely be giving you a call. Thanks for the offer. I've been keeping up with your build thread for Boomer as well. I'm looking forward to next year's adventures.
Re-reading your post makes it obvious that it wasn't yours. I don't know why I thought it was. Your Ex is nice. Beautiful scenery as well.
It is what I wanted. Panel sides, swing out side door, and the right wheelbase. I know Ford is the common choice around here for a van conversion, but I think the AWD Express van platform might be enough. In the end, the Excursion stays though. The van really doesn't offer me enough to make up for the downsides of abandoning the Excursion. I would still want a pop-top on the van and if I am going to do that, it would be better to do it on the already built and mechanically sound Excursion.
I didn't plan on doing the roof this year, but one thing led to another and now I have no headliner. So, the roof rack had to come off next. I'll have to find a way to remount the light bar. Some parts ordered, some brackets made. Friday I start work on making a template of the roof and mockup the new pop-top roof. Interior build is on hold until the new roof is in.
I will definitely be giving you a call. Thanks for the offer. I've been keeping up with your build thread for Boomer as well. I'm looking forward to next year's adventures.
Re-reading your post makes it obvious that it wasn't yours. I don't know why I thought it was. Your Ex is nice. Beautiful scenery as well.
ExploringNH
Explorer
Starting work on the mold master for the fiberglass top today. I have tackled some pretty interesting engineering problems this week and am hopeful. I knew undertaking a project like this would be a large amount of work but every single little detail requires several hours of "figuring out". I've redesigned the lift arms about 5 times and I need to redesign them again. Keeping a low profile roof is challenging. Every way you can think of to keep a lower profile brings other issues. I want to keep the ability to install a roof mounted bed which limits a lot of design options. If it wasn't for that bed, the roof profile could be made about 1.5-2" lower.
This is a very rough draft of the design. Everything is to scale but the elements will all change a bit. I don't have an accurate Excursion model to work off of and I'm not about to invest the time to make one. Today I'll get a profile of the roof and go back and apply that to my model. That is as far as I will take it.
This is a very rough draft of the design. Everything is to scale but the elements will all change a bit. I don't have an accurate Excursion model to work off of and I'm not about to invest the time to make one. Today I'll get a profile of the roof and go back and apply that to my model. That is as far as I will take it.
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