Ultimate Expedition 4wd Camper Van & Tow Rig

NLPRacing

Observer
My wife and I have decided to put our motorhome up for sale and purchase a travel trailer. I want to build the ultimate E-Series van to tow the travel trailer and to use it an “Expedition” camper as well as something to “tailgate” with at NASCAR races & NFL games. What I want to start with is an EB with a diesel and then I'll add a raised roof & my own interior (at least 4 captain's chairs, power reclining sofa bed, bathroom with RV style toilet & small sink, cabinet with fridge, microwave & some storage, etc. and the obligatory electronics to keep the kids from saying “are we there yet”). I would also like to add the UJOINT 4x4 conversion with a mild lift to accommodate 33” to 35” tires. Basically, it would have the features we enjoyed in the motorhome while traveling, but can still be used as a regular “conversion” van for daily driving when need be.

Ideally, I would like an E350 window van with factory rear A/C, cruise control and either the 7.3 or 6.0 Powerstroke diesel. As I am looking thru Craigslist, eBay, Autotrader, etc., I am discovering this combination to be hard to find. There are quite few diesels, but they are mostly E250 cargo vans and if they have less than 200,000 miles, they are pretty proud of them and most E350 window vans are of the 15 passenger variety with the 5.4L gas V8. I'm sure if patient, I'll find what I want, but while searching, some crazy ideas popped into my head.

LSR-FT.JPG
The difference in length from an RB to an EB is 20”, but the wheelbase is the same, 138”. My crazy idea is to find an E-Series chassis with a 158” wheelbase and mount an EB body on it. Preferably, I would like to find an E450 cab/chassis with a diesel and a 158” wheelbase. I got this idea when I was looking at pictures of Chris's V4 project, especially the pictures of the frame with the cab removed. I have seen many of E450 cab/chassis for sale, some with less than 150,000 miles (mostly former ambulances), for anywhere from $1500 to $5000 depending on age, mileage & condition. My idea is to take one of these and buy a van with a good condition EB body and do a “body swap” mounting the EB body on to the E450 chassis and rework the quarter panels moving the fender wells 20” towards the rear. Then I would “bob” the frame on the E450 essentially making a LWB EB. This idea really intrigues me due to the higher GVWR/GCWR on the E450 chassis as well as the rear axle being closer to the rear of the van which is ideal for towing. Another advantage to this is doing any work and/or upgrades to the engine & the UJOINT conversion will be much easier when the cab is off.

I even thought about using the very rare E550 as the base vehicle.
1.jpg
I found one nearby that has a 158” wheelbase and a 7.3 Powerstroke with less than 150,000 miles. The GVWR/GCWR on it would allow me to add pretty much whatever I wanted. But, I'm not sure if the body would mount to the E550 frame nor do I know how hard it would be to convert to 4wd.

Has anybody heard of or seen anybody do a body swap involving an E450 or E550 like what I have described? Is this too crazy of an idea?
 
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I'm sure (without specific experience however) that someone can competently convert this to 4WD. Preferably using a Dana Super 60 or larger.
There are many many places that do custom body work on the ultra common US mfg trucks, I don't think that the body swap will be a problem.

Charlie
 

bknudtsen

Expedition Leader
Interesting ideas... IMHO, the cost of doing the body swap will outweigh any benefit derived from the increased wheelbase. The entry price will be so much lower with the regular wheelbase. That money saved can go into all the extra things you want. Having said that, if you decide to tackle the 158" project, please document the build here.

Oh, and since your are talking custom body work, rather than reworking the wheelwells, you could use an RB body cut and lenthened right after the front doors.
 
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NLPRacing

Observer
Interesting ideas... IMHO, the cost of doing the body swap will outweigh any benefit derived from the increased wheelbase. The entry price will be so much lower with the regular wheelbase. That money saved can go into all the extra things you want. Having said that, if you decide to tackle the 158" project, please document the build here.

Oh, and since your are talking custom body work, rather than reworking the wheelwells, you could use and RB body cut and lenthened right after the front doors.

I thought about using an RB body (or even an EB body) and then filling the gap between the existing cab & new body, but then the side doors would be 20" away from passenger door making for a pretty goofy looking vehicle. When it's all done, I want it to look as if it could of been factory. Besides, I don't think it would be as hard to "re-locate" the fenderwells 20" to the rear as you think it would be. There's also plenty of these vans in wrecking yards that I can cut sheetmetal off of. My preliminary plans would be to do most of the sheetmetal work pre-body swap.
 

LukeD

Observer
Stumbled across this doing my usual search for parts and such on Craigslist in Fresno where I live

http://fresno.craigslist.org/ctd/3203564004.html

Pretty rare, took me 3 months to find a 15 passenger diesel :sombrero:

Looked like this one before (except obvious color difference) what it looks like now
DSCN0616.JPGDSCN0792.jpg
 
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notmiller

Observer
Interesting idea! Using a van body, you'd have to replace the rear axle of the 450 or 550 since I think they all come as dualies unless you want some super wide fender flares (I very well may be wrong). Try playing around with the "stretched" concept in Photoshop and post your results. I think we'd all be interested to see!
 

McZippie

Walmart Adventure Camper
The difference in length from an RB to an EB is 20”, but the wheelbase is the same, 138”. My crazy idea is to find an E-Series chassis with a 158” wheelbase and mount an EB body on it. Preferably, I would like to find an E450 cab/chassis with a diesel and a 158” wheelbase. I got this idea when I was looking at pictures of Chris's V4 project, especially the pictures of the frame with the cab removed. I have seen many of E450 cab/chassis for sale, some with less than 150,000 miles (mostly former ambulances), for anywhere from $1500 to $5000 depending on age, mileage & condition. My idea is to take one of these and buy a van with a good condition EB body and do a “body swap” mounting the EB body on to the E450 chassis and rework the quarter panels moving the fender wells 20” towards the rear. Then I would “bob” the frame on the E450 essentially making a LWB EB. This idea really intrigues me due to the higher GVWR/GCWR on the E450 chassis as well as the rear axle being closer to the rear of the van which is ideal for towing. Another advantage to this is doing any work and/or upgrades to the engine & the UJOINT conversion will be much easier when the cab is off.

Pitch you this idea... buy a new or used Chevy/GMC extended van that already comes stock with Durmax diesel and 155" wheel base and add a Quigley conversion.
Been toying with this idea myself.

http://www.quigley4x4.com/Gallery/GMProducts/GMProductPhotos.aspx

0608dp_07_z+quigley_4x4_diesel_vans+duramax_chevy_express.jpg


255560_4532632318438_732535094_n.jpg
 
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ujoint

Supporting Sponsor
Those factory 450's are leaf sprung too. Not sure of the spring pad width, but they have massive leaf spring hangers.
 

NLPRacing

Observer
Pitch you this idea... buy a new or used Chevy/GMC extended van that already comes stock with Durmax diesel and 155" wheel base and add a Quigley conversion.
Been toying with this idea myself.

http://www.quigley4x4.com/Gallery/GMProducts/GMProductPhotos.aspx

These GM vans actually contributed to my idea of a LWB Ford van. The problem is, I'm a Ford guy. Even if it made more sense to start with the GM van, I would rather stick with a Ford. Even if that means I have go with a E350 with a 138" wheelbase and EB body. If I could find a Terra Bus like yours, that would really be my first choice.
 

NLPRacing

Observer
Stumbled across this doing my usual search for parts and such on Craigslist in Fresno where I live

http://fresno.craigslist.org/ctd/3203564004.html

Pretty rare, took me 3 months to find a 15 passenger diesel :sombrero:

Looked like this one before (except obvious color difference) what it looks like now
View attachment 118017View attachment 118018

Your van looks great. I'll keep an eye out for a 15 passenger diesel, you never know when one will pop up. Speaking of, I did find this one: 2003 E350 Diesel EB Quigley 4x4
$(KGrHqV,!nkF!HISVZK7BQPU9,yO,g~~60_12.JPG
It's a Quigley, but I'm sure I could have Chris convert it to a "UJOINT" style for me. ;)

Those factory 450's are leaf sprung too. Not sure of the spring pad width, but they have massive leaf spring hangers.

Did you mean 450 or 550? The E550 does have leaf sprung front solid axle, very similar to the one under my 2004 F53 motorhome. I wonder if a F550 front axle would "bolt" up to the factory pads? Then add a transfer case, driveshafts and be done. :)
 

ujoint

Supporting Sponsor
Oh yea, re doing a Q van right now! It's messy, but someones gotta do it :D

I'm pretty sure the stake body van shown earlier is a 550. So my last post was a typo. 450's are standard coil spring, the 550's were mono beam leaf spring. Need to find one & take some measurements!
 

McZippie

Walmart Adventure Camper
These GM vans actually contributed to my idea of a LWB Ford van. The problem is, I'm a Ford guy. Even if it made more sense to start with the GM van, I would rather stick with a Ford. Even if that means I have go with a E350 with a 138" wheelbase and EB body. If I could find a Terra Bus like yours, that would really be my first choice.

Hard to find a Turtle Top Terra used, that doesn't have an all glass passenger door.
Believe me I know what you mean about being a Ford guy... although this Chevy school bus has possibilities. FS at Davey Coach.

TerraTrans4X4Trax.jpg
 

Saiyan66

Adventurer
If you plan on using the E550 chassis, make sure you take some measurements of rear axle centerline to shackle in the rear. I believe that the springs are much longer on these chassis configurations and you wouldnt want the rear of your leaf spring and shackle hanging past the end of the body. That would be the limit on how much you could bob the end of the frame.
 

NLPRacing

Observer
I sold my motorhome this week. I'm going to to try to find a diesel 15 passenger van in the next month or two. If I can't find what I want, then it will be time for plan B (E450 Cab/Chassis). :)
 

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