Originally Posted by m-chan68

As a Ford dealer tech, I too would be very interested in this project. Here are my two cents, for what little it may be worth.

2005 was a very interesting model year for the Excursion, in that it carried over the front leaf spring suspension setup of the '99 to '04 model year Super Duty F-250/350 trucks, I would guess being due to Ford by then had already planned the Excursion's demise, therefore chose not to update it the way they updated the rest of the Super Duty lineup with coil springs up front as well as a completely different brake, driveline and overall suspension setup front and rear. Also interesting to note, 2005 saw the introduction of the 5.4L 3-valve and 6.8L 3-valve V10 engine choices for the gassers, which replaced the previous 2-valve engines. This obviously wasn't case for Excursion applications. They also carried over the exact same instrument panel and interior layout of the preceding model years. In fact, the only things I can think of on an Excursion which are 2005 specific are the grill and front bumper, as well as the 2005 and later version 6.0L engine (with the beefier cast iron V4 HPOP and EGR throttle plate deleted), if so equipped. There are actually a lot of 2005 model year Excursions with 2004 6.0L engines in them.

The wheelbase on an Excursion is shorter than an F-250 Crew Cab short box. I will assume you will be modifying the frame during this project as needed, to account for this? Will you be retaining the updated suspension and brakes of the newer generation Super Duty trucks? I would hope so. What will you be doing with the Excursion specific rear interior trim, to make it match the updated 2012 style interior of the F-Series? Lastly, are there any issues with the 2012 F-250?

Brainfart. The Excursion uses an after axle metal tank like the Cab and Chassis F-Series trucks. The DEF tank and plumbing are also different on the midship fuel tank applications versus the after axle fuel tank applications. How will you be addressing this, along with the fuel fill door? Are you planning on equipping this with rear heat and rear A/C? How do you plan on "networking" the controls for such, into the factory F-Series controls?

Sorry for all the questions, but I do admire your ambition. I will also assume the intended product to be what it would look like, if Ford had chose to keep it in the model lineup right through to 2012?

Originally Posted by Randy_270

Awesome build! Random question, any way for someone who doesn't use the spare tire holder on a Super Duty truck to switch the fuel tank to an after axle fuel tank for better side to side weight distribution? I'm just guessing it would help out those, like me, with the Super Duty lean.

Originally Posted by Randy_270

How big are Ex fuel tanks? All I got is about 22 gallons max and I want a bigger tank. But it would probably be a lot easier just to add air bags to level out the back rather than switch to an Excursion fuel tank.

Originally Posted by pdombrowicki

The frames will be spliced from part of the EX and the F250. The Ex will have all the running gear and suspension from the 2010 F250. Also all electronics from the 2012. The things that are Ex specific will be wired into a new fuse box and work like the original Ex did. All modified Ex's will have factory air and heat. Controls will be separate guess like the original Ex's where. The Ex keeps it's original plastic fuel tank and will get the sending unit out of the 2012. Not sure what we are going to do with DEF yet. Hope to pipe a filler neck under the hood. All interior trim will be painted to match the 2012. This is a perfectly straight almost brand new truck with 27,000 miles. Hope this answers some of your questions.

Originally Posted by pdombrowicki

I am sure it is possible. You would need some kind of pump or switch to go from one tank to the other. Plus pluming the fuel lines.

Originally Posted by m-chan68

A dual fuel tank option does exist on F-450 and F-550 applications.

Originally Posted by pdombrowicki

Got any pictures?

Originally Posted by m-chan68

Originally Posted by pdombrowicki

DEF tank is separate from the fuel tank. Why would I replace the Ex tank? Just going to add the DEF tank.

Looking for pictures of the tanks.

Originally Posted by Powerdude

There is a company that does this already. They have been in business for a while.

2012 Ford Excursion Conversion