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Here we go with just another build thread! I posted in October 2023 about my newly acquired 2005 Excursion and we’re finally getting started on the build. Lots of research, changed my mind numerous times on various components, ordering parts and so forth and so on. Anyway, better late than never. I’ll keep posting as we progress through the build and I’m sure I’ll have lots of questions along the way. Feel free to chime in with ideas and suggestions.
Overview & Goal
I’m not building a rock-crawler or ultimate off-roader. Rather, I’m looking for a very capable, reliable & comfortable machine built with the best components. Maybe a little bit bug-out truck, just in case. This will be a semi-daily driven truck.
Chassis, Axles, Suspensions, Brakes, Wheels & Tires and Steering – Basically Everything Below the Frame Rails – All Work Being Performed by Alabama Truck Outfitters
Axles
I bought a 2016 F250 4x4 donor truck and we're using those axles. Sterling 10.5 out back and Dana 60 upfront. Yukon 4.56 with Detroit True Trac in the rear and Eaton Elocker in the front. All new components such as Tom’s driveshafts, Hellwig swaybars, Synergy steering, etc.
Suspension
Hutch's Welding full air ride on all corners - 1994-2022 Ford Super Duty – Hutch's Welding (hutchswelding.com)
I ordered the Leveling Kit as it will give about 2” – 4” of lift with the axle swap. Also new adjustable 3-link radius arms front & rear and Fox shocks. I’m really intrigued by the whole set-up and can’t wait to give it a test drive. Also going with new S & B body mounts.
Steering
Redhead steering box, Borgeson steering shaft and all new components
Powertrain – Engine, Transmission & Transfer Case Engine
Aaron @ Northwest Industries of MT is building me a V10 similar to the one on this thread. Going all forged internals and yes, it’s grabber blue. Acufab, Banks headers, electric water-pump and radiator fans, high-amp alternator, etc., etc. Performance 2V V10 - Ford Truck Enthusiasts Forums (ford-trucks.com)
Transfer Case
Eliminating ESOF and going to convert to manual stick. Refurbish stock case.
Exterior & Interior
I’ll post more details once I get to that stage of the build, but going with a 2016 front-end conversion, Buckstop bumpers at both ends, #16K Warn winch, lights, etc.
Interior will all be refreshed with new infotainment, carpet, seat covers, headliner, etc.
We all know a thread is worthless without a few pictures, so here’s the first of many more to come.
Holy cow, talk about a "money is no object" type build,,,,I like it.
Since you seem to be going all top shelf style on parts, there is a far better option for the steering box than a redhead remanufactured box. That would be an all new and redesigned PSC steering box, it's a drop in replacement. Links below to the steering box I'm talking about
I checked into the PSC box, but seems it wouldn't fit a V10 Excursion? I'll call them to make sure.
While I love DIY'ing my stuff and could "probably" do all this work, I just don't have the time. Once ATO is done with chassis stuff, I'll do the rest of the work myself except for body & paint.
I checked into the PSC box, but seems it wouldn't fit a V10 Excursion? I'll call them to make sure.
While I love DIY'ing my stuff and could "probably" do all this work, I just don't have the time. Once ATO is done with chassis stuff, I'll do the rest of the work myself except for body & paint.
Thanks
2016 f250 axles and air suspension don't just "fit a v10 excursion" either, so it might require ever the slightest bit of custom fabrication. Will the shop not do anything that doesn't come as a "kit" or something?
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I’m very much looking forward to following along with lots of pics!
Do you already have the Banks headers? Story about a month or two ago was that they were no longer going to be made and were unavailable. If true it’s a real shame, mine have been great for about 12.5 years now with lots of heavy towing miles on them.
I’m very much looking forward to following along with lots of pics!
Do you already have the Banks headers? Story about a month or two ago was that they were no longer going to be made and were unavailable. If true it’s a real shame, mine have been great for about 12.5 years now with lots of heavy towing miles on them.
If the banks headers are no longer being made, then we need to find a set to dimension and replicate
If the banks headers are no longer being made, then we need to find a set to dimension and replicate
Why??? If there was enough sales volume to matter then Banks would still be making them.
For the one or two people left out there that still want to modify a v-10 ( vice swapping in say a new Godzilla engine), then it’s custom fabricated headers for them.
The ford v10 never really saw much aftermarket support for some reason. IMHO there are several far superior choices of engines to pick from, both gasoline and diesel. I’d own/drive a v10 ex, but if the engine ever needed to come out, I couldn’t see myself putting it back in.
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Just use the 2011-16 steering gear. I've been running an OEM box since mid 2018ish and it's doing fine.
You'll need to drill the mounting holes out, but the bolt pattern is the same. 3x 10.9 16mm x 2.0mm x 130mm bolts.
I got my hardware from Bolt Depot.
Why??? If there was enough sales volume to matter then Banks would still be making them.
For the one or two people left out there that still want to modify a v-10 ( vice swapping in say a new Godzilla engine), then it’s custom fabricated headers for them.
The ford v10 never really saw much aftermarket support for some reason. IMHO there are several far superior choices of engines to pick from, both gasoline and diesel. I’d own/drive a v10 ex, but if the engine ever needed to come out, I couldn’t see myself putting it back in.
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I guess because I fabricate parts for a living, I am looking at it through the lens of dimensioning existing to make it easier to build a set for anyone who'd want them, or in case I end up with a v10 someday. I'm not interested in pursuing some niche in business that banks abandoned, I'm merging my business with my enthusiasm and suggesting I'd make some for people who would want them, i.e. other enthusiasts. I would not be interested in making custom headers every time a v10 crossed my path for fabbing, and the person who was looking for headers wouldn't like my price to do so.....
2016 f250 axles and air suspension don't just "fit a v10 excursion" either, so it might require ever the slightest bit of custom fabrication. Will the shop not do anything that doesn't come as a "kit" or something?
Shop is well versed in fabrication, so we'll check it out today.
Do you already have the Banks headers? Story about a month or two ago was that they were no longer going to be made and were unavailable. If true it’s a real shame, mine have been great for about 12.5 years now with lots of heavy towing miles on them.
I have a set of headers, might have gotten the last one!
