Started this project last year. 2003 E450 cutaway, 7.3 turbo. Added a 42" cab extension and a 06 Super Duty F series dually bed.

Now painted and being re-assembled, interior going in as well as the A/C-Heat add on unit made for a limo.

I really like these chassis, factory dual batteries, dual alternators, 55 gallon fuel tank, 158 WB and rear outputs for A/C and Heat lines.














Project should be finished in the next 3 weeks or so......

Jon

 

That is awesome! Nice work man. Did you do all the body work and painting yourself?

 

I can't paint........the assembly and preparation of parts....all that stuff...yes...Paint no.

Glad you like....

 

How did you do the extension?

 

Unless I'm dreaming I recall this from some time ago? At any rate its looking very nice and I'm looking forward to seeing more of your progress too!

The cab extension is very interesting.

 

Project started last year. I posted the concept of the van truck then.

I had the cab back extension custom built by the fine team at Cabbacks.com. They did a great job for me and they themselves really liked the 42 inch extension. They now offer it in their lineup of products.

I purchased another E450 as well as another extension from them to build another truck. This time I am changing the front sheetmetal/grille to 08-11 standard and using a 2011 superduty pickup bed.....stay tuned.

Jon

 

i love its awesome ,good job

 

More photos

 

Curious. Presume the doorless 42" extension is fiber glass? What is it for, a sleeper? Or will there be seating & mods to front seats for better access?

Have you added up total cost for "Frankenstein"?

Doesn't FORD make a Super Duty dually Crew Cab?

 

Good Questions..

Yes, the extension is fiberglass. Will contain a 4 passenger bench seat (Ford Club Van) and a limo heat and air unit 15K BTU under the bench. Lots of leg room!

The front passenger seat will slide back 15 inches allowing easy entrance and exit for rear passengers.

Yes....I would love a superduty dually quad cab. But......I am using Frankenstein about 5 times a year to tow a enclosed gooseneck trailer.

It will be idle most of the time. I priced quad cabs with the 7.3 and clean, low mileage units were 16 to 18+k.

I am in to this build when finished for under 10. Having turned the learning curve, the next build will be in the 6 to 7 K range.

Obvious to me that the lesser cost would pan out relative to my intended application.

Some day if I pull more trips I might consider a quad cab, but till then......I am sticking with the E series.

Thanks

 

Interestingly enough, the paint job was the single most expensive part of this conversion. Body shop removed bed, painted bed, fenders and tailgate. Replaced 2 fenders on cab with new ones, painted door jambs, the works. Charged $3500 including material. Screaming deal, but still the single largest ticket item I had to deal with.

Second unit will be less.....2011 bed is NEW, just off a NEW superduty crew cab, had rhino liner and had the gooseneck hitch platform.

No paint needed there......just paint cab....saving bucks there.

Jon

 

Jon I like how this is shaping up for you---from what I gather the end result will be somewhat specialized to your needs or wants. Some of us are the cookie cutter, off-the-rack kinda people, others more of the custom made variety.

Within my own business other companies and one-man shops think how I've out fitted my work van is a bit over-the-top, spent too much, not needed etc etc. Since I'm now in process of outfitting my 4th E250 I'll continue to refine my ideas until its exactly what I want. The cost comes down, time to convert is less along with the cost too---all upsides to my way of thinking!

What sort of glass will you use for the extension side walls? (I'm in the auto glass business which is why I ask.)

Hope to see more as your progress continues--very interesting!

 

The windows I used are made by C.R. Laurence Co. The side windows were found on e-bay and were surplus, new in box. From an old RV company contract I would think. I calculated the curve of the frame of the window to what I was dealing with on the fiberglass shell and they were perfect.

Price was excellent in line $35 each. Had I special ordered the same window from C.R. Laurence Co, they would have cost me in the hundreds of dollars. The lower panels slide up and have screens.

Installation was simple, using bytyl tape and a metal mounting flange supplied. Some simple shimming on the inside with paint sticks and the windows were in. No leaks,,,looking good.

The rear is a C.R. Laurence Co ford pickup rear window with slider....around $200...fits in the windlw flange of the extension with a special rubber gasket supplied with the window.

The guys at cabbacks.com were very helpful, as i sent them a sample side window and they cut the mounting holes in the side of the extension for me.



My goal is to tow the gooseneck trailer and have extra seating in comfort. To do all of this with a practical, economical approach. So far, so good. I have a good looking, powerful machine at a very attractive cost to reach my goal.

Now on the comfort factor...the interior....stay tuned.

 

I'd be droolin if that was a 75-91 E-F350 van truck

 

what wheel base vans r you using