The Ute II: E350 RB 7.3 ZF6

[jblaze5779]

Hi, where did you get the new boots for the turbo to intake connection?

 

[naterry]

Hi, where did you get the new boots for the turbo to intake connection?

There's a few out there, but this is the shortest 90 I found: http://www.amazon.com/gp/product/B00CB2353O?redirect=true&ref_=cm_cr_ryp_prd_ttl_sol_0

 

[naterry]

God Bless Plasma Cutters!

Now that fuel capacity has been addressed it's time to make use of the aft axle dead space. The plan is to keep a small battery bank, the air compressor, water pump, Espar, and recovery gear down there. Basically things that are heavy or loud and rarely accessed. The space will be 26 x 26 x 12.

 

[mk216v]

Flinstones!

 

[devo 1]

No problem. Note that the "perfect" way to do this would be with two threaded couplers and locknuts. I went the quick and dirty route because it was literally the last thing I did on the conversion and was excited to get the van on the road! This is just an extension using a threaded rod, two nuts for alignment, and a quick weld. It's ugly, so I only half admit that it's my doing... :costumed-smiley-007

Thank ya, sir! I didn't have a clue. The salvage yard didn't have the part so I made one.

I put a nut on both sides and a locknut.

 

[derjack]

Now that fuel capacity has been addressed it's time to make use of the aft axle dead space. The plan is to keep a small battery bank, the air compressor, water pump, Espar, and recovery gear down there. Basically things that are heavy or loud and rarely accessed. The space will be 26 x 26 x 12.

...

Hi,

I would be concerned about loosing the strength that the "X" shape holder for the spare tire is giving to the frame.
We know that the Ford "C" frame is not the strongest in terms of twisting. Cutting out crossmembers does´nt help of course.

Though I am actually planning to add a tank in the rear as well. Though with 2 additional single crossmembers before and after the Tank/ skip plate.

PS: In Germany the car would loose its licence to drive on the street immediately, if noticed in an inspection (every 1 (over 3,5tons) -2 years)! :Wow1 In generall: Welding on the frame is not allowed. Drilling into the frame is ONLY allowed on the vertical side of the frame and a special points, not everywhere. Hangers like the leaf-one from Ujoint, are not allowed- because they strengthen the front frame that is weakend by Ford to make a crash "softer" for the other party.
Car life is so easy in the US :smiley_drive:

 

[naterry]

Now that fuel capacity has been addressed it's time to make use of the aft axle dead space. The plan is to keep a small battery bank, the air compressor, water pump, Espar, and recovery gear down there. Basically things that are heavy or loud and rarely accessed. The space will be 26 x 26 x 12.

...

Hi,

I would be concerned about loosing the strength that the "X" shape holder for the spare tire is giving to the frame.
We know that the Ford "C" frame is not the strongest in terms of twisting. Cutting out crossmembers does´nt help of course.

Though I am actually planning to add a tank in the rear as well. Though with 2 additional single crossmembers before and after the Tank/ skip plate.

PS: In Germany the car would loose its licence to drive on the street immediately, if noticed in an inspection (every 1 (over 3,5tons) -2 years)! :Wow1 In generall: Welding on the frame is not allowed. Drilling into the frame is ONLY allowed on the vertical side of the frame and a special points, not everywhere. Hangers like the leaf-one from Ujoint, are not allowed- because they strengthen the front frame that is weakend by Ford to make a crash "softer" for the other party.
Car life is so easy in the US :smiley_drive:

Yeah I went through multiple TÜV inspections when I was living there and modifying my car for the Grüne Hölle. It always made me nervous but I obviously stuck with approved components and thus never had an issue. And I agree, modifying vehicles is virtually impossible in most of central and western Europe. It cuts both ways though, here we have people jacking cars up and putting huge rims and thin tires on their cars and thinking it's safe, stuff that would never even come close to passing any real inspection.

The rear crossmember is certainly there for structural reasons, but it's also beefed up to support the spare tire. I'm adding a frame below the storage box that stiffens a longer section than the OEM tire mount and also acts as a skidplate.

 

[derjack]

Hi naterry,

I made my experiences with TüV when I was young.
With an E350, Germans have NO experience, or clue. Especially with special ones like mine, an ambulance with 4 link + air.
But a technical clean change with regard of some rules can make it happen. Gas/diesel tanks need a pressure test also, or factory tank. I hope a cutaway tank will fit to not need a pressure certification...

Share some photos of how YOU fit your solution under the body....

 

[naterry]

I made some progress on the rear storage this weekend. Anyone doing this should note that the Ford E/F series frame C-Channels tend to splay out when the rear cross-member/spare tire mount is removed. This suggests that the frame members have significant internal stress from the factory and thus require all cross-members to keep them in position. Aftermarket parts like stiff bumpers and tow hitches help alleviate the need to add bracing back in, but they only the tie the very rear of the frame together and that is 4+ ft from the rear shock mount cross-member on an RB van.

Here's what I did. It was quick, simple, and ties the frame together mid span between the rear and next cross-member. There are certainly more elegant, robust, and lightweight solutions but time was a factor.

Note that this frame does not connect to the rear storage box. The frame should be free to flex independent of the body within the limits of the pliant body mounts. It does support the bottom of the box through a rubber pad, but does not inhibit the movements that happen when the frame twists.

I like the exhaust coming out as far back as possible so I offset the storage to make room for the re-routed tailpipe:

Now it's time to plumb and wire! Two trojans, the air compressor, Espar D5, and recovery gear now have a new home! :costumed-smiley-007

 

[DzlToy]

What was wrong with the fuel cell?

Great idea, seems like that is a decent amount of below-the-floor storage space.

:beer:

 

[naterry]

What was wrong with the fuel cell?

Great idea, seems like that is a decent amount of below-the-floor storage space.

:beer:

Haha, I figured someone would catch that. ATL was supposed to send me the aluminum box when I ordered it for the track car so when they finally sent the right one they let me keep the old steel box. Works great though, and fit perfect.

 

[mk216v]

Great reuse, and I love the motorsport inspiration!

 

[naterry]

Cheers!

In other news I finally replaced the weeping water pump with an Airtex AW4114 (OEM manufacturer, but cheaper). Also replaced the main hoses, pulleys, 206deg Thermostat, and added a coolant filter for good measure. The filter kit goes for 120$ here: http://www.dieselsite.com/1994-199773lcoolantfiltrationsystem.aspx. It was a pleasant surprise to find the billet mount, bracket, filter, fittings, and hardware for such a low price, seems rare these days.

 

[Arctic Travelller]

Will the batterys be in a sealed, vented box? Hydrogen gas might not play nicely with the heater's flame.

 

[naterry]

Will the batterys be in a sealed, vented box? Hydrogen gas might not play nicely with the heater's flame.

Indeed, and good safety note.

Figuring out the plumbing on a "utilities box" is fun. Fuel in/out, coolant in/out, air in/out, and wiring in/out. Good times!