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1968-Present E-Series Van/Cutaway/Chassis Econolines. E150, E250, E350, E450 and E550

Door panel modification

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Old Aug 30, 2013 | 07:45 AM
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Door panel modification

This may be a strange or silly question, but has anyone done any driver door panel mods to relocate the power window switches? That part of the door panel is too close to my leg and it interferes with my 'comfort zone'. I'd rather that whole area be smooth and flat so I have more room and more choices for where I can position leg while driving. Ideally I'd also like to move the inner door handle but that seems to be a lot of work... This is my first post-91 Econoline and there's less space between the door and me than in the older models.
 
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Old Aug 31, 2013 | 12:47 PM
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Have you checked other years and trim lines in the series? Maybe there's a door panel arrangement that can be retrofitted or you can get complete doors.

Sixto
93 E150 Chateau 5.8 186K miles
 
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Old Sep 9, 2013 | 11:09 AM
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Originally Posted by tabijan
Have you checked other years and trim lines in the series? Maybe there's a door panel arrangement that can be retrofitted or you can get complete doors.

Sixto
93 E150 Chateau 5.8 186K miles
I haven't checked any other years, no. And with it being a custom painted conversion, it wouldn't be worth replacing the doors. The panel seems to be one molded piece, so it looks like some fab work will probably be in order if it's that important to me. This is the only complaint I have with this beauty.
 
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Old Sep 10, 2013 | 07:09 AM
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Not familiar with the door panels of your year but maybe check out the '97 and later versions? To wit:



Does that relocate the switches to a better place?
 
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Old Sep 10, 2013 | 07:32 AM
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Actually, it does. The map/umbrella pocket at the bottom would have to come out though. The end goal is being able to park my left leg in the step well, like I used to do with the pre-91 models. Thanks for that pic, it gives me hope. I'm going to go grab a picture of mine for reference.

*edit, here's my door panel, and you can see how the door switch is compared to your photo.

 
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Old Sep 10, 2013 | 09:07 AM
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Wow---that is quite different and not at all inconvenient. Well if you wanted to scratch your ankles while using those switches maybe it would be?

When I was shopping for door panels the typical used/salvage yards were my eventual choices. New they run anywhere from $450 to almost $900 each I'd try eBay and LKQ too since both are nationwide outlets.

You'll probably find eBay the least desirable since UPS shipping something that size runs over $50. LKQ would transfer it into your local outlet or somewhere close enough driving wouldn't be too huge an issue.

BTW the later model panels should be a direct swap. You'd want the donor door's master switch assembly and wiring harness too--graft the new one onto the existing chassis wiring and you'd be good to go.

My van is an '03 but between '97 and '02 that rather large lower pocket wasn't available. Those can be somewhat easily removed because they're held to the major panel with clips. They're handy but no doubt get bashed quite a bit on fleet vans.

Anyway hope this helps----good luck in your quest!
 
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Old Sep 10, 2013 | 11:36 AM
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It's all about the incursion of that silly switch panel over the step well, making it all but impossible for me to find any measure of comfort there. It's also quite low as you stated, making you have to memorize the controls in order to use them while the van is in motion. Thanks for your input, it is extremely helpful and does definitely give me some good ideas.
 
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Old Sep 10, 2013 | 01:33 PM
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Good enough then----glad to have helped if even a little!
 
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Old Sep 10, 2013 | 06:10 PM
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Originally Posted by WarrensE350
Actually, it does. The map/umbrella pocket at the bottom would have to come out though. The end goal is being able to park my left leg in the step well, like I used to do with the pre-91 models. Thanks for that pic, it gives me hope. I'm going to go grab a picture of mine for reference.

*edit, here's my door panel, and you can see how the door switch is compared to your photo.

the most perfect spot for long cruises. Break out the dremel and find just the top have of any interior door you want and shape it to fit! the only other thing i can think off the top of my head is that you will need to fab up a new latch rod that opens the door.
 
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Old Sep 11, 2013 | 05:59 AM
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That's a good idea LSx but since the door shells are pretty much the same even down to the latches, handles, hinges etc the door trim panel attachments allows later years to fit all the way back to '92.

The later years would fit perfectly in place, the only modification maybe being splicing a different master switch connector at the end of the door wiring harness. As I look at Warren's door though its possible the later year switches are the same apart from their appearance and location.

Sometimes we're custom tailoring people living in an off-the-rack world!
 
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Old Sep 11, 2013 | 06:44 AM
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Well, I'm up for a little 'plastic surgery'. It'll be a while before I get going on it (honey-do supercedes it, of course) but I will let you know the results. Thanks again for the tips.
 
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