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Long time Lurker - such a great site and resource. There are several great Excursion builds on this site - I think I've read them all 2-3 times. Y'all have inspired me to share my current project.
Project X - or how to turn $20k in cash into a $10k vehicle.
I still remember when the Ford Excursion was first announced back in 1999. We HAD to have one. Naturally, we bought one the first year it came out. The subject vehicle: 2000 Ford Excursion XLT 7.3L 2wd. Over the next 18yrs it has served as the family Truckster and tow vehicle. Pulling the camper, and all manner of trailers.
Sadly, it had endured some physical abuse and has scars to prove it.
Rusty rockers.
Collision damage.
Not to mention several dents from minor mishaps.
With rust, body damage and 240k miles, we debated replacing the trusty X with a new shiny 4dr truck. We wanted a 4X4 since we’ve begun venturing off-road with our JK Wrangler and would like to do some light wheeling with our tow vehicle. After shopping, research and test drives, we concluded there just isn’t an adequate replacement for the X. So contrary to good sense and judgement, we’ve decided to restore the X and make it the expedition vehicle we want.
Since we wanted to convert it to 4wd and we needed body panels, it seemed obvious we should look for a donor vehicle. Donor to the rescue!!
Enter a 2002, 4wd, V10. This is it's good side - which works out, cuz we need the quarter panel. The 2002 is rust free, but the interior is RAGGED OUT. There's collision damage in the front right fender and door - we need neither. The truck runs well, the 4wd works and we drove it onto the trailer.
First order of business is for the donor to start donating. If you're gonna cut a hole, might as well cut a big one!
We'll be a bit more delicate with Project X.
Donor quarter trimmed up and ready for the first fitting.
First fitting - pretty close.
Almost ready for the paint booth. Getting a full re-spray!
In the meantime - The UPS man stopped by.
A little time after work enabled me to get the front axle ready to drop out.
Now where are those friends of mine with weak minds and strong backs?
Got the front axle out.
Stripped the steering, swaybar, track bar off then degreased and power washed.
Brakes off and sitting in the shop. Ready to start the tear down!
We can see from the oil stain that the passenger side axle seal has been leaking. No problem - we'll be doing a full rebuild.
Fully disassembled! Time for more cleaning.
Still lots of work to do . . . . Meanwhile . . .
The X is out of the paint booth, reassembled and looking like new!
Still have the spare on the left rear - since the OEM wheel was damaged in the collision. Worry not, new wheels and tires are on the list!
Ok, back to the shop . . .
I made a set of check bearings, measured/labeled all my shims - yeah, I know, super ****!
Just cursive if you considered doing a coil springs front suspension since it is being converted or did the appeal of only 1 donor vehicle since you need the 1/4 panel rule that out ? Either was a awesome effort.
Just cursive if you considered doing a coil springs front suspension since it is being converted or did the appeal of only 1 donor vehicle since you need the 1/4 panel rule that out ? Either was a awesome effort.
Yeah, I seriously considered the coil front swap, but as you say, I already needed an excursion donor so when I found the 4x4 it was a no brainer. Besides the simplicity of the leaf spring suspension has its appeal - and I have a JK Wrangler for serious off-road duty.
CR
Yeah - sort of. Used the Blair Enforcer Spotweld Drill (same folks that make the Rotobroach bits). Awesome device. It holds the metal from bending as you drill close to the edge of the flange; doesn't leave a pilot hole; can be adjusted for depth and diameter. Leaves the panel ready to weld with minimal grinding and cleanup.
Thanks, the enforcer looks awesome but I don’t like to drag the Co2 bottle for an air supply to the recycle yard where I salvage a panel from.
Looks great for in the shop though ( and a couple on eBay for $300 lol so I’ll likely get one )
fwiw... the Blair rotobroch doesn’t use a pilot hole but you have to centerpunch the spot weld and the bit has a spring loaded tip that keeps the cutter on task. Doesn’t leave a hole in the back panel as long as you can control your pressure and not drill through it. A stop like on the enforcer is a great thing.
There are a bunch of sources online for outer rockers - cheapest I found was MillSupply
I'm not sure I've seen inner rockers available. Mine were fine so we coated them with POR-15 and called it good.
CR
There are a bunch of sources online for outer rockers - cheapest I found was MillSupply
I'm not sure I've seen inner rockers available. Mine were fine so we coated them with POR-15 and called it good.
CR
4.30 gears in! Axles installed with new u-joints. Knuckles installed with new ball joints. All new bearings and seals.
Almost done with the front axle!
CR
