I'm making this the official build thread. To see how it all came about, see this link:
https://www.ford-trucks.com/forums/1...nt-enough.html

Here's a complete detail about what was done today, Day #1.

Since I can't do the swap at home, I have some space in my grandparents' garage to get it done. I got out there at 9:05 AM this morning to prepare for the Excursion to arrive between 10 and 10:30. I had to put a trailer outside that had been stored inside, and also unload all the tools I brought out. Here's the '05 ready and waiting...



The driver called when he was about a half hour out, which was at 10:20. Since I have a somewhat challenging location, I told the driver I'd meet him up at the highway and lead him in. Here was the drive out to the highway, in the snow:



Waiting:



Finally here!




Backing into the neighbor's driveway. Mine is too narrow to have room to unload this, but we're all connected, so I was able to go right through.



I have help from my grandpa. While the driver pulled the straps off, my grandpa cut the tape/plastic to open the driver's door. Being only like 5'4", he fit in quite easily. One of the many things I brought in the back of the Excursion was a freshly charged air compressor. Since the bead on the back tire wasn't broken, I was able to re-inflate it enough to pick the rim up. We tried to start it, but the batteries were so dead, we didn't even have the slightest lights. So, we cleared out of the way and he put it in neutral:



Well, due to the flat tire, he couldn't steer it enough and it went crooked. Fortunately the brakes worked enough to stop it before it went off, but it did knock the ramps off their mounts.



The driver put the ramps back on and we hooked up to a chain to help persuade it. We got it down safely with no other issues:



The towing company got to go on their way, and according to camera times, they were here for just under 20 minutes. Not bad at all:



Now, we had to change the flat out with the spare. I took the hubcap off and got the spare unwrapped and out of the back while my grandpa went to get the jack:







New batteries in June 2011, but they are DEAD:


Got some other pictures while waiting:




Got the spare put on, ready to roll:




Towed it to the house. Fortunately we never hit, though there was one close call. I was watching closely though, so I hit the gas and got out of the way:








Had a Dept. of Defense sticker for Ford Campbell on the windshield...

 

looks like the beggining of a very cool project. when it comes time to part out the remains of the donor vehicle lmk. I would be interested in a few things.

 

Next, I dropped a couple extra batteries in it. Got the one from the '05 and the battery from my trailer:




Got the mud cleaned out from the front. The front valance just fell off once the mud was brushed out



Got the entire windshield cut out and in the trash. Then onto vacuuming up all those little pieces:






Next, I decided to try to start it. I checked all the fluids (except I now see the power steering), and all was good except engine oil. Apparently some leaked out in the rollover, as it wasn't even showing on the dipstick. I added 6 quarts of some 10W-40 we had sitting around the garage and it brought it up to the range. We'll be changing it later anyway. Then, I got myself in there and glow plugged it twice. Cranked but it didn't turn over right away. I got out and went to the other side to check the fuel cutoff switch, which I forgot to do before. It wasn't tripped, so I went and got back in to give it another shot. Two more glow plug cycles and it finally turned over. Didn't stay running long, so I had to crank it again. It stayed running that time. I don't think that was bad considering it has been sitting since the accident on 11/6/2011 and it's ~32 degrees out. Hopefully this works:

******** width="400" height="224" ><param name="allowfullscreen" value="true" /><param name="movie" value="http://www.facebook.com/v/2434846919012" /><embed src="http://www.facebook.com/v/2434846919012" type="application/x-shockwave-flash" allowfullscreen="true" width="400" height="224"></embed>*********>

This meant I was able to get it in the garage under its own power:



Unlike what I said earlier, we later found the power steering cap partially off and very low. Topped it off with some fluid and started it again. Power steering is much easier now, but there's a lot of air in the system and it's very noisy.

Now I took some more pictures to document it. I've got more, but here's a few. Quite a few were a little blurry too, so I'll have to re-do some of them.

 

How we finished the night:


Jon

 

Yep, I got a lot of "I wants" building up buddy for when you part that puppy out!

I can't wait to see the journey this thread is going to cover!

Stewart

 

Send me a PM. I'm planning to part the interior stuff out soon because I want to make room to put all these engine parts.

 

Subscribed! Good luck with the build.

 

I forgot to mention, the best part of the day. When I was sitting in there listening to it warm up:



And with 3/4 of a tank of fuel:


This makes me very excited!

 

Awesome build! Although I like the Cummins swap idea others have, this one is quite unique. Finding a donor for the price you did made it that much sweeter and easier. Good luck! I'll be watching this one.
BTW, this IS the time to adress upgrades such as uppipes, glowplugs, etc.

 

You guys didn't waste anytime taking that X apart! I would love to buy the spare tire cover. I can't wait to see the progress pics. Keep us all posted please!

 

wow

sub'ing to see the awesomeness

 

One thing I forgot to mention is even though it was originally brought in with a clear title (which allowed me to bid on it to start with), when I was given the title today, it was branded as a salvage title with the seller/owner being Farm Bureau Insurance. I might call them about that tomorrow. Not that it really matters to me one way or the other since I won't be rebuilding it, but I'm hoping it won't be a problem to get it in my name.

I suspected something was up when the Autocheck report no longer ran. Good thing I saved a PDF of it early on. I wondered if it had something to do with it being reported at an insurance auction, but now I really know why.

 

If You have a webcam you can stream live video for us junkies on youstream. It's a free service and would be nice to watch the suspense.

Here is the link.. USTREAM, You're On. Free LIVE VIDEO Streaming, Online Broadcasts. Create webcasts, live stream videos on the Internet. Live streaming videos, TV shows

If you decide to run a live show just post the link to your show here and im sure their will be lot's of enthusiast tuning in to watch. Pretty pleasssse?

 

I'd love to, but I have no internet connection out there

 

Finally, after another half hour of uploading, here's another video I took, a walk-around with it in high idle. Sounds much better here after it started to warm up.

******** width="400" height="224" ><param name="allowfullscreen" value="true" /><param name="movie" value="http://www.facebook.com/v/2435769582078" /><embed src="http://www.facebook.com/v/2435769582078" type="application/x-shockwave-flash" allowfullscreen="true" width="400" height="224"></embed>*********>