MG Metalworks Van Build

[mgmetalworks]

I'm testing out a lot of theories with this Cummins swap and one of them is that I think I've found a way to remove the Advancetrac/RSC from my van without affecting the remaining modules in the vehicle. It involves some new parts and some module programming trickery but logic tells me it will work. You never know until you try, right?
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I found a VIN# for a bare-bones 5.4L van with no RSC and then tracked down the main wiring harness for this van. As an exciting surprise, the harness came populated with fuses and relays...which is nice considering that they're hard to find and they're expensive. The harness didn't cost as much as I thought it would...under $400. Brand new, direct from Ford.
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As another pleasant surprise, the APPS (Accelerator Pedal Position Sensor) wiring uses the same connector as the Chrysler APPS assembly so the wiring is already integrated into the harness...probably saving me hours of wire routing.
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So... lots of wiring and module programming fun lies ahead. :sombrero:

 

[bknudtsen]

That sounds promising!

 

[philos]

I'm just floored by your fearlessness and your great approaches to problem solving!

 

[mgmetalworks]

I'm just floored by your fearlessness and your great approaches to problem solving!

Fearlessness? I like that! Thank you!
:beer:

 

[mgmetalworks]

I've been rounding up the parts for my new fuel system which includes one of these....
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Yep, a 55 gallon aft of axle tank out of an E-450. When I finally have everything in hand I'll probably be in it a little over a grand for the whole change over. This tank came with the straps and I'm trying to figure out a way to hack the cross members out of a cut-away van at the local Pick 'n' Pull without expending much effort to get the rest of the mounting hardware... It does look like one of the cross members in my current frame can be re-purposed without much trouble. I am capable of making parts to fit too if I can't get the factory cross members.
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For those who are curious, the tank is ~37" long, a shade under 32" wide and (with fuel lines and filler neck and straps included) ~15-16" tall. Looking at how it will mount under the body, I think it will hang down at the same level if not slightly less than my spare tire does now. I'm not that concerned about it hanging down though... it is super stout and I'll probably build a skid plate for it to take the initial punishment.
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The spare tire cross member will have to come out, one other cross member has to move and then I need to add in two other members for mounting. Not too bad but I'm planning on doing this when the body is off the frame for the Cummins swap to make it even easier. The filler neck looks to come out in just the wrong spot and will have to snake around the factory rear A/C stuff somehow but that's all part of the fun. The front fuel door will become the filler location for the Diesel Exhaust Fluid tank and the rear fuel door to fill the big tank. I could conceivably leave the factory tank in for massive amounts of fuel but I'm taking it out so I can have room for the DEF tank and other accessories that I might have put in the back.

 

[philos]

Tank envy...


Sent via flux capacitor

 

[bknudtsen]

I'll let you practice burning the spare tire crossmember out on my rig when I am down there next weekend... :sombrero:

 

[mgmetalworks]

All I can say today is ARRRRGGGGGH!!!
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I received the engine to trans adapter parts and let's just say that I'm not impressed with the quality. You can't see it very well from the pictures but these parts aren't up to the standard that I'm holding this engine swap to.
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Porous casting, very rough machine work, the cheapest materials used, weld splatter everywhere, counterbored holes that should really be countersunk... the list goes on.
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I was hoping to not have to do this but like so many other things, I'll just have to design better parts myself and have billet pieces made.

 

[philos]

Yeah, you can see that's a funky casting. Looks like it was poured into a silly-putty form backed with construction paper...
I guess now that you're fearless and all, it should be no sweat to mill one out in your spare time.
Sorry about the crap parts


Sent via flux capacitor

 

[dcguillory]

hope they didnt cost much/are returnable

 

[boardrider247]

It's sad but you can actually tell that those parts are bad from the pictures.
Are the bolt patterns at least correct? That way they can be used as mock up's or reverse engineered to save you a little time designing your parts.

 

[mgmetalworks]

...they can be used as mock up's or reverse engineered to save you a little time designing your parts...

Funny you should mention that... :sombrero:
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I have the new parts mostly done in Solidworks already by taking measurements off of the ones I just got.

 

[mgmetalworks]

It took nearly a year to get these but I've finally got them in my hands and I can do with them what I want!!! Original 3D data from Ford for the E-series frame and various F-series suspension parts. I'm seriously frickin' excited about my next year's worth of development projects!!! :wings:
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[java]

Sweet! Where did you procure those models from?!

 

[mgmetalworks]

I got them legitimately... I'll start by saying that. :sombrero: Ultimately it was through a design firm with very close ties to Ford but I started by persistent inquiries to the Body Builder Advisory Service and was directed elsewhere. I'm not kidding when I say that it took a year to get these...