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74 E300 Resto-mod Build
Thought it would be fun to post up my progress on my resto-mod build. Little background and pics in my introduction page: https://www.ford-trucks.com/forums/1...-supervan.html
Fast forward to now...I have the entire Van stripped down to just a rolling chassis. Old drivetrain is out. I purchased a complete running and driving 2000 Mercury Mountaineer AWD 5.0L for $900. 124k miles. Stripped that down to just about nothing. Kept about every piece I thought I was going to try and use. Realized I won't be using much of it as far as wiring and such. Sold the catalytic converters for $200 and the wheels and tires for $300. Very happy with that deal!! I took the AWD transfer case off and sent the 4R70W to a local transmission shop to swap the tail housing and output shaft to a 2WD set-up. They went through it and replaced seals and gaskets. Said it was in immaculate condition. I started ordering minor bolt on upgrades such as TFS valve spring kit, Scorpion 1.6 RR, ARP headbolts, New FPP hydraulic roller lifter, Comp Cams hardened push rods, Comp Cams dogbones. Even with 124k miles, this motor was immaculate. Pulled the valve covers and not a hint of sludge. Routine oil changes goes a long way guys! Cylinder walls still had great cross hatching. Didn't feel the need to touch the bottom end at all. Pulled and cleaned both heads, cleaned and lapped the valves, new gaskets throughout the entire motor. HV oil pump, ARP oil pump shaft, new water pump, harmonic balancer, front cover seal, double roller timing chain, ARP crank bolt and cam bolt. All new sensors, new bosch in injectors, all new everything. About 95% put back together... Holley Terminator X Max for 98+ MPFI harness kit. Pretty overkill in my opinion, but will have this new set-up running perfect in this old Van. American Autowire Highway 22 Plus chassis wiring kit. All new wiring from front to back for this thing. Will be running all LED lights. Jegs special long tube headers and will have a custom exhaust built when that time comes. I have a local aluminum welder making me a custom dimension fuel cell. 34" x 24" x 10". Approx 35 gallons using stock filler neck and has internal baffling. Running a Tanks Inc. adjustable height fuel pump assembly. As of now, I have a stock replacement Carter fuel pump and in tank regulator, but haven't decided if I'm going to use them yet. Eastwood aluminum radiator also at the welders to modify some mounting tabs and inlet tube. A lot of odds and ends still need to be addressed, but with the weather getting colder it's currently on hold for a little. Any comments and suggestions are welcome. Thanks for checking out my project SuperVan. -Tom |
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Cool project and write up. Looking forward to your progress. I think the 5.0 engines were one of the best manufactured by Ford.
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Thanks Jimbo, I totally agree with you about it being one of the most solid motors Ford has put out.
Initially, I had huge ambitions to LS swap it, but this being my first ever serious swap, I wanted to keep it rather “simple”. I thought I was going to use the complete OEM harness from the Mountaineer, but that quickly became more of a hassle than it was worth. Holley makes it all possible. In hindsight, the only difference between my current swap and a LS swap would have been conversion motor mounts and trans crossmember! HA! Oh well... |
Got to mess with the ignition key cylinder. Carefully took it apart and cleaned all the old built up gunk. Very tedious removing all the little cylinders and springs. Made sure to lay them out in order. Re-greased and put back together.
Also cleaned up the old turn signal assembly. Hard to find a replacement for these. One on eBay for $150, ouch. Maybe go dash mounted push buttons with self-cancelling module?? https://cimg9.ibsrv.net/gimg/www.for...ae7603229.jpeg https://cimg0.ibsrv.net/gimg/www.for...56f1f0344.jpeg https://cimg6.ibsrv.net/gimg/www.for...35f30ece4.jpeg https://cimg7.ibsrv.net/gimg/www.for...3f6a6cb68.jpeg https://cimg8.ibsrv.net/gimg/www.for...480389f57.jpeg |
So stoked, just scored a complete front disc brake swap on good’ol eBay!
It’s off of a 74 F250. Dual piston calipers with brackets and even the dust shields in great shape! |
This is SO cool!
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I so love this project.
Where I work we used to have a woodshop teacher who back in 2000 found a 1974 Ford E100 that'd been parked in a garage most of its live, it had less than 50,000 miles on it. He drove it to work once in a while and it looked brand new. |
Quick question. I notice that the part description for the Holly system has +trans. So it will control the trans too? Did you have to order it specific to your motor/trans combo? Are/did you change the rear gearing to take advantage of the overdrive?
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Originally Posted by wiskeyVI
(Post 19651431)
This is SO cool!
Originally Posted by James Doty
(Post 19651988)
I so love this project.
Where I work we used to have a woodshop teacher who back in 2000 found a 1974 Ford E100 that'd been parked in a garage most of its live, it had less than 50,000 miles on it. He drove it to work once in a while and it looked brand new.
Originally Posted by Spaznaut
(Post 19652561)
Quick question. I notice that the part description for the Holly system has +trans. So it will control the trans too? Did you have to order it specific to your motor/trans combo? Are/did you change the rear gearing to take advantage of the overdrive?
I have not changed the gearing yet. I honestly don’t even know what gearing I have, but I plan on beefing it up eventually with a posi and optimal gearing ratio once I get it all together and running. |
Gonna suggest you start looking for a radiator, the heavy duty unit used in these vans, it is a rare find, or have one custom made because you are gonna have an issue cooling that engine, mine overheats every trip across to Cherokee NC, glad to see there is a guy on facebook that is making the fan shrouds, its for the heavy duty V8 radiator. I'd like to get a nice roller engine for mine, it still has the 302 put in when built in73, even the c4 transmission is original, about time for a rebuild. Great job on that, This is the guy making fan shrouds, tho I don't see it listed, you can contact him to order one: https://customvan.com/catalog/index....66d2lpaevltns5
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Do you not have the oil fill tube that extends up to strap under the hood, what you currently have will require pulling the doghouse to add oil?
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Originally Posted by maples01
(Post 19656097)
Gonna suggest you start looking for a radiator....
With the addition of an electric fan, I’m hoping it keeps it cool enough. I mentioned in my first post that it’s currently at my welders to get the mounting flanges flipped and the inlet tube angled in.
Originally Posted by maples01
(Post 19656134)
Do you not have the oil fill tube that extends up to strap under the hood, what you currently have will require pulling the doghouse to add oil?
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I swapped in a flex fan 6 blade for the factory 4 blade, van had the same fan you got on a model A, I will Never use an electric fan, mine got so hot it seized, they are designed to run momentary, under load you'll burn one up. The radiator mounts to the front of the firewall, those brackets are on the wrong side, but I did see one that sit into the front making it flush with the firewall, putting it closer to the fan, not sure how well it cooled. I just want to say aluminum radiators are common in todays cars, disposable, which is not a good thing, tho I did get a heavy duty one with wider cores for my E350 10 years ago, need to watch the coolant, it can damage it if left too long.
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Decent weather today for the most part. Mid 50’s with some sun.
Got to cut out and grind down the original gas tank brackets to make room for the new fuel cell. Wire brushed the underside, cleaned it up, and sprayed some sound deadener and bed liner combo. Had some left over cans laying around. I think it came out alright. Also removed the fuel filler neck and was blown away at what I found jammed in the old rubber portion of the fuel filler.....an old busted section of a fuel cap, top section of a flippin broken glass bottle!?, and a rock! HA! What the heck!? Got a good laugh. https://cimg6.ibsrv.net/gimg/www.for...26b5c7fe6.jpeg https://cimg5.ibsrv.net/gimg/www.for...b646f79f5.jpeg https://cimg0.ibsrv.net/gimg/www.for...332365c10.jpeg https://cimg2.ibsrv.net/gimg/www.for...dc1af773a.jpeg https://cimg6.ibsrv.net/gimg/www.for...c091f6d2e.jpeg https://cimg4.ibsrv.net/gimg/www.for...43a2109a5.jpeg |
Sanded and repainted the steering column and gas filler neck too.
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That's crazy. Why the hell would someone jam a broken bottle in there? Gotta wonder what the heck the deal was with the gas cap as well?
Your paint job looks good. |
Originally Posted by James Doty
(Post 19657541)
That's crazy. Why the hell would someone jam a broken bottle in there? Gotta wonder what the heck the deal was with the gas cap as well?
The gas cap piece has a lock on it and looks bent up, maybe owner lost the key and tried to pry it off and it broke and fell in and he said screw it haha. Glass bottle piece....maybe someone tried using a glass bottle as a funnel for gas or something Lol?? Maybe just plain vandalism... The rock....maybe vandalism along with the glass bottle piece.
Originally Posted by James Doty
(Post 19657541)
Your paint job looks good.
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You removed the tank brackets, what are you planning to put in its place?
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Originally Posted by maples01
(Post 19658025)
You removed the tank brackets, what are you planning to put in its place?
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I need a tank, damn ethanol rusted mine, can't pay to have one custom made tho.
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Disc brakes
Originally Posted by BOOM_FIST
(Post 19651290)
So stoked, just scored a complete front disc brake swap on good’ol eBay!
It’s off of a 74 F250. Dual piston calipers with brackets and even the dust shields in great shape! |
Originally Posted by 72van
(Post 19668147)
hey Boom fist. Nice project. Im collecting disc brake parts for my e300. I havnt taken my original brakes off yet. How does the caliper bracket bolt to spindle. It looks like i need another part? Do you have any pics or input. Thanks.
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Originally Posted by 72van
(Post 19668147)
hey Boom fist. Nice project. Im collecting disc brake parts for my e300. I havnt taken my original brakes off yet. How does the caliper bracket bolt to spindle. It looks like i need another part? Do you have any pics or input. Thanks.
https://cimg8.ibsrv.net/gimg/www.for...fd79d3018.jpeg So the main pieces you’ll want to get you hands on are the caliper mounting brackets. These are hard to find and pretty pricey when you do. Well worth it in my opinion. These guys: https://cimg1.ibsrv.net/gimg/www.for...e7de440c5.jpeg https://cimg2.ibsrv.net/gimg/www.for...bcf65d3a4.jpeg These will mount directly to the E300 front drum spindles/knuckles. If you look at the backside of your factory spindle, you’ll see 4 bolts that have the same pattern as these caliper mounting brackets. This is all in theory, but should be a direct bolt on from the research I’ve done. I will update this as I pull my factory spindles off to do this swap. |
Finally got my American Autowire Highway 22 Plus wiring kit. It was backordered for a bit.
Looks really nice and I’ve heard a lot of great things about this kit. A bit pricey, but I wanted something that was going to remove the stress out of figuring out the body wiring. This is it. I’ll update as I start getting into laying the wiring out. https://cimg8.ibsrv.net/gimg/www.for...26ddb6ad6.jpeg https://cimg0.ibsrv.net/gimg/www.for...7e3017e9c.jpeg |
Way cool build! Your work looks fantastic and that van will definitely move down the road 👍
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Originally Posted by Howellbuilt
(Post 19679462)
Way cool build! Your work looks fantastic and that van will definitely move down the road 👍
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Checked in on my welder, James, for my fuel cell and he sent me some pics. So stoked to see it in person. It’s a shame really.....it’s so pretty and I’ll just be stuffing it underneath the Van. Haha
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Wow, nice fuel tank, quite a few people need one, their are rusted worse than mine, is it the same size as the stock one or a little larger?
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Finally got to play in the garage tonight. Messed with the new brake booster and the steering column.
It’s an 8” dual diaphragm booster and I’ll be using the brake master cylinder off of the Mountaineer. Had to slot the mounting ears on the MC for it to fit the new booster. Comparing new to old. https://cimg2.ibsrv.net/gimg/www.for...d23630a23.jpeg https://cimg5.ibsrv.net/gimg/www.for...c97eda173.jpeg https://cimg7.ibsrv.net/gimg/www.for...15b0b14cc.jpeg Had to fab up the MC plunger bolt and booster linkage. MC plunger was too short so I found a longer bolt with the same thread and cut the head off. Ran to the hardware store and bought a shorter coupler nut and cut the threaded portion of the original linkage. https://cimg8.ibsrv.net/gimg/www.for...c18510688.jpeg Final product. 🤙🏽 https://cimg0.ibsrv.net/gimg/www.for...335d8f6d0.jpeg Found a steering column bearing that matches the steering tube and shaft dimensions perfectly. Installed it on the lower part of the steering shaft in place of the factory plastic bushing piece. Had to cut 7.5mm off the bottom of the tube to get the shaft clips to line up for the original upper bearing. https://cimg8.ibsrv.net/gimg/www.for...acfbfb183.jpeg https://cimg9.ibsrv.net/gimg/www.for...37e075b9c.jpeg https://cimg1.ibsrv.net/gimg/www.for...dd110da8a.jpeg |
I used a heim joint end to make a throw rod for mine, due to manual pedal on the power booster, different throw.
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Picked up my fuel cell and radiator this past Sunday from my welder. Beyond impressed with the outcome. Also received my NOS turn signal switch off eBay.
34 gallon tank https://cimg6.ibsrv.net/gimg/www.for...40afd6254.jpeg Tri-flow radiator https://cimg7.ibsrv.net/gimg/www.for...d71798662.jpeg https://cimg8.ibsrv.net/gimg/www.for...6ae66a7e3.jpeg Old vs New turn signal switch https://cimg5.ibsrv.net/gimg/www.for...fe6b88d3d.jpeg |
Got to work on the fuel pump assembly.
Took a stock replacement Carter fuel pump assembly for the donor vehicle (2000 Mercury Mountaineer) and tore it apart. https://cimg1.ibsrv.net/gimg/www.for...9b2d46253.jpeg Took the fuel level sending unit and mounting plate off the stock assembly by drilling the spot welds. Measured and cut the depth for the aftermarket adjustable fuel pump assembly. Marked the holes for the sending unit plate to be riveted on. Had to play with the height of where I wanted it to read EMPTY and then just made sure the float arm wouldn’t hit the top of the tank on FULL. I think it came out perfect. https://cimg1.ibsrv.net/gimg/www.for...9764b70b4.jpeg https://cimg2.ibsrv.net/gimg/www.for...37df58dab.jpeg https://cimg3.ibsrv.net/gimg/www.for...697c1206d.jpeg https://cimg7.ibsrv.net/gimg/www.for...5d4776b3c.jpeg |
Can’t believe I found another set of caliper mounting brackets on eBay for a good deal. Just got them in the mail today. Impulsive buy, but I have an idea for them.
I’m going to find someone that will reproduce these brackets. Maybe get a few prototype sets made to see how much interest there is before making a bunch?? Don’t know...we’ll see I guess. https://cimg5.ibsrv.net/gimg/www.for...1780629f6.jpeg |
Originally Posted by BOOM_FIST
(Post 19698237)
Can’t believe I found another set of caliper mounting brackets on eBay for a good deal. Just got them in the mail today. Impulsive buy, but I have an idea for them.
I’m going to find someone that will reproduce these brackets. Maybe get a few prototype sets made to see how much interest there is before making a bunch?? Don’t know...we’ll see I guess. |
Originally Posted by JWA
(Post 19698933)
Before you invest your own money like this think long and hard. There's just NOT as huge a market for these as you might believe---if there was money to be made someone else would have long ago brought them to market. Even if "everyone" here or any other sparsely attended old van forum says its a good idea its really not. I don't mean to bash your ideas but would hate seeing you spend a lot of money for something that's not needed or highly sought after.
Thoughts and ideas come and go, Lol this one was pretty quick....haha Well, if anyone is interested in these for their project, shoot me an offer. |
Hello Boom_fist
following your story, thanks for sharing. Respect for your job. Wonderful Club Wagon. Can’t wait the next ... ;) |
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