UJOR Build Thread

[ujoint]

I thought I'd take a few minutes & start a detailed build thread for a van I'm currently working on. This van is an 02 E350 EB, 7.3 diesel. This van is getting all the goodies! 6" lift, OBA, front & rear bumpers, winch, on board H2O, lockers, etc. I'll update info & pics as quick as I can!

1st step, install front spring hangers while still 2wd

Springs installed, ready for the axle...

Axle & steering installed

I removed the factory spare tire holder to free up some space underneath. This new x-member has been welded in to strengthen the frame, and the rear skidplate will be installed behind it..

Here's how the van sits now, 6" lift on 35x12.50 17's. More updates tomorrow!!

 

[RocKrawler]

I'm still curious about the shackle hanger install at the back of the front spring. Is there a jig for getting the correct angle? Pics? Looking great so far!

 

[ujoint]

Locating the hole is easy, and I did mock up a jig with this van. I should have some cut out soon.

 

[RocKrawler]

Locating the hole is easy, and I did mock up a jig with this van. I should have some cut out soon.

Excellent- that was the only "tricky"part getting it lined up and squared on the SAS kits I sold at my previous employer, without a jig it would have been a total shot in the dark getting it right the first time. The Toyota's also have a surprise in the boxed frame in the form of a diagonal sheet metal brace that likes to grab hole saws.

 

[dsw4x4]

Curiosity question

It appears that you are plating both sides of the frame (can't tell from the pictures, just a guess) but it looks like you are plating both sides of the factory ford crumple zone and using this crumple zone to support the weight of the van. Is there more support that goes inside the frame or inside the frame rails? That area of the frame is designed to give way easily to impacts therefore not giving it the stability of a boxed frame. My other question is are you sleeving the bolts through the frame? I tried mounting components through the frame with out welded in dom sleeves and it failed under severe stress. Like a said just curious every once in a while I get people wanting me to do 4wd conversions but I have not done a leafspring conversion on a van yet.
Derek

 

[ujoint]

The Toyota's also have a surprise in the boxed frame in the form of a diagonal sheet metal brace that likes to grab hole saws.

The Ford vans do too, 2 small braces in a triangular pattern. They're easy to get out of the way or remove.

My other question is are you sleeving the bolts through the frame?

Yes, the frame becomes boxed once the brackets are installed & every bolt is sleeved with a piece of 3/4" DOM. My part 1 install video shows them being installed. The rear bolts are in the solid frame section, so the load of the hanger is spread out.

 

[ujoint]

Rear x-member/skid plate supports got installed today, as well as the rear ARB & front True Trac.

 

[Sheep Shagger]

It looks like you have changed the rear shock mounting points. (Ones on the frame, not axle). So you can use shock with an eye mount rather than stem mount. That opens up a whole new set of options for shocks if that's the case. Any info on this change?

 

[ujoint]

It looks like you have changed the rear shock mounting points. (Ones on the frame, not axle). So you can use shock with an eye mount rather than stem mount. That opens up a whole new set of options for shocks if that's the case. Any info on this change?

Are you talking about the front or rear?

 

[Sheep Shagger]

Are you talking about the front or rear?

Sorry, Rear. I know you have weld in ones for the front.

 

[ujoint]

The rear just has a stem eliminator up top, nothing special.

 

[Sheep Shagger]

The rear just has a stem eliminator up top, nothing special.

Thanks, I didn't realize anything like that existed.

 

[ujoint]

Chasing parts for the last 2 days, but we got the Aluminess bumper & Warn 16.5 installed today. Finally have a full day in the shop tomorrow for some wiring & plumbing....

 

[Topher Walters]

Chris,
You were able to get the Warn 16.5 in the Aluminess bumper. I was told that it would not fit. Mine is the 2007 version of the Aluminess not their newer bumper.

 

[ujoint]

Yea, I never asked, so I'm making it work. You have to rotate the winch and re mount the control box. I'm making a small simple bracket to make everything fit. I'l post a pic when it's done.