Jaleo 2- Building a 2012 E-350 4x4-Third time is the charm

[Raul]

After 5 years with the Rig Runner, there were some things I wanted to upgrade: Rear Locker, Full floater rear axle, front locker, bigger tires... I figured that it will be easier to build a new van from scratch than replace things. It's been almost three months and it may not be that easy. I get the same feeling as with parenthood; they said that in order to keep procreating, human beings forget the misery of raising a baby. I start to feel the same way about building a van...

Anyway, This will be my third Econoline build. The second 4x4. The idea is to travel with my brother-in-law this summer and sell the RigRunner in September

Here is the Jaleo 2 next to the Rig Runner:


This is a 2012 E350 by-fuel (CNG and Gasoline) 5.4l with 135k miles. Took a while to find a decent price low-ish miles unit. The market is crazy in these pandemic times.

First thing was to strip it down and take care of a couple of rust spots on the floor. Other than that is completely rust-free.




I use Total Boat Rust Primer and then regular primer and paint. I like Total Boat beacuse is liquid and can be spayed with a hand sprayer on hard to reach areas like all over the frame.

Sound deadening was next.


Stall mats will be the base for the flooring. Those things are HEAVY!


First exterior modification: New headlights (great, I love them) and aux lights on the blinker space since the headlights already have blinkers (I love the look, but they are pretty much useless)



New head unit and S-pod knock off. I like them both. I' working on tilting the head unit towards the driver since reflections make the screen hard to see.

 

[Raul]

First Fill up with CNG. You got to love the price of gallon equivalent. Since gasoline tank is untouched, having CNG can work as a range extender.






After filling it up, it run on CNG for a few miles with a lot of hesitation and, after that, it is not changing to CNG. Hopefully I'll be able to fix it without paying an arm and a leg. I'm learning this CNG business as I go.

Roof rack, solar panel and exhaust fan. I am replicationg the set up of the RIgRunner.

 

[Raul]

Axle from a 2011 F350. Rear e-locker and 3.31(?) gears. Next is to install a front Posi Yukon DuraGrip and 4.56 gears.


Wheels and rims ready. 35/12.5r18. Do not get me started on the price increase on these things. For what I paid for the rims and tires on the RigRunner four years ago I can not buy just the tires. Awning lights installed on the roof rack.


I got a good deal on 4 brand new rims (Vision 417 bronze) but they are discontinued and I can not find a matching spare.



Working on the wiring I need to find the spots to put all this stuff:

1. Lithium battery
2. 1500w pure sine Inverter
3. DC to DC chanrger
4. MPPT solar controler
5. Fuse box
6. Diesel heater

To be continued....

 

[Raul]

Some progress on the interior. All wiring run, Panels upholstered. Next will be to fit the 2nd row Explorer seats and do the fridge/microwave module.

On the mechanical side, I'll start tearing down the front Dana 60 to fit the LSD and 4.56 gears.

 

[Raul]

Another step forward. Electric panel, shore/inverter switch, roof rack light switches done. The heater is placed with the floor holes drilled. Working on the Ford Explorer seats' brackets. They will be cross-braced, gusseted, and reinforced.

I don't what to hear again these vans are overpriced. I forgot how much work you punt into these things.

 

[DCaves]

Just finished reading your Rig Runner build. Very much so looking forward to this build thread! Awesome work and I appreciate the pictures! Looking at a 2012 extended E350 and want to do something similar. Van I might purchase has a low level hum at all speeds, so need to get that sorted first.

 

[Raul]

Not much to do with the seat brackets until I get the gas tank out. Time to move to the Axles.

Front: Dana 60 with Yukon Dura Grip Slip differential, 4.56 gears
Rear: Ford 10.5 with e-Locker and 4.56 gears.






Didn't want to re-gear but 4.3 axles were had to find and since I was re-gearing I went I step up to 4.56.

Front Gear and Differential Bearing pressed in. I do not have a large press, but I have an oven. 1.5 hours at 350F did it for the ring gear. I just slid in. I heated the bearings fro about 30 minutes and had to hammer them in a little bit.

 

[CaptainBuilt]

Looking good! Love the new rig!

 

[RVflyfish]

Love the oven trick.

 

[CaptainBuilt]

Love the oven trick.

Me too. I've seen the deep fryer one, not the oven lol.

 

[Raul]

Axles are done. I wasn't able to use the Yukon Dura grip as this carrier was for a thin ring on 4.56 and above gears and there is only a thick ring on 4.56 reverse rotation gears. Since I already mounted the ring I cannot return it.

I got a Speedmaster TorqueWorm LSD wich is a Torsen type differential. Very excited to see how it performs.

Ready to start tearing down the front 2WD axle and start the install.




SuperLift control arms as in the RigRunner. They are not crazy expensive and I like the extra clearance they provide.

 

[Raul]

Making progress. Axles installed. Still need to weld in place the spring and the shock absorber perches. Love the stance. The springs lift a little bit less than the RigRunner but with bigger tires is almost the same height.



With the old steering linkage I did my signature track bar reinforcement. On the 2012 van the linkage has already a kink so no need for a bracket.



It took me 6 hours to get this sucker out. BFH, torch, grinder...


I got a great deal on a new set of 6" lift spring for a 2000ish F350. They were ridulously tall, but I Frankenstein a hybrid set. Will see how it works. Top is the new set, bottom is the old, middle is the hybrid with the old master and two leaves from the new set.



Precission equipment.


As my daughter said: it doesn't look like a kidnaper van any more.



Next:
* Finish rear axle . Perches, shocks.
* RE-build the transmission
* Cut gas tank
* Finish seat brackets and bolt them wiht the gas tank out.
* Rear bumper wiht swing outs. With the CNG tanks I have no room for the spare underneath.
* Install winch. Retaing the OEM bumper.
* Bed platform
*...to be continued...

 

[tcg144]

How did you mount the control arms? Custom mounts or did you get them from MG, etc

 

[Raul]

How did you mount the control arms? Custom mounts or did you get them from MG, etc

I’m using the MG kit again.

 

[b. rock]

So, what's with the track bar reinforcement? Just trying to avoid any chance of flex in that area?