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2012 Excursion Conversion
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Building a 2012 Excursion out of a 2005 Ex and a 2012 F250. Started this project before Xmas. This is for a customer of ours and I have tons of pics to share.
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Customer dropped off his 2012 CC Larriet today for a 4dr Excursion Conversion build starts next week. Look for a lot more pictures to come.
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Progress so far. Truck up on the frame rack so we can straighten the quarter. Gutted the interior and have all the wiring pulled out, striped and labeled for the conversion.
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Started on the Excursion today. Drilled out the floor and outer rockers, Need to cut the inner rockers and the windshield pillars and the front part body will be lose. Pulled the rear drive shaft so all we have to do is cut the frame and roll the body, frame and motor and tranny of the frame rack. The 2nd row seats from the Expedition EL showed up today.
Attachment 34311 Attachment 34312 Attachment 34313 Attachment 34314 Attachment 34315 Attachment 34316 Attachment 34317 Attachment 34318 Attachment 34319 ---AutoMerged DoublePost--- Got the front end off the Ex today. Attachment 34320 Attachment 34321 Attachment 34322 Attachment 34323 Attachment 34324 Attachment 34325 |
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Got the rest of the body off today and the tank drained, gas, brake lines, electrical wires removed. Also have the rear axles all unbolted and ready to roll of the rack.
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Got the frame cut on The EX today. Rolled the front half off with the motor and trans still in the frame. Rolled the back axle off and outside to. Put the 2012 on the frame rack and gutted the interior. Monday call for the windshield to be cut out and started taking everything off the underside off the truck.
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Pulled the running boards, bumper, spare tire, hitch and everything underneath. Drilled the floor and rockers out. Hope to have everything cut a part tomorrow.
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Sent EX frame, gas tank Sheild and hitch out to be sandblasted today. Got it all back today to. Great turn around time. Got the 12 all cut a part. Just got to roll the back half off the frame rack.
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Got everything epoxy painted. Next week to work on welding the frames together.
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We have separation! Time to start putting it back together.
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Frame is all welded together.
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Welds all cleaned up and painted. Slide the axle out from under the box and put it under the Ex frame. Decided to use the springs from the truck so we have to move the front spring perches forward 8". Going to have the drive shaft shorten from the 12.
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Spring perches moved forward and all tided up. Gas tank and Shield back in. Start messing with the Euro tank.
Attachment 33933 Attachment 33934 Attachment 33935 Attachment 33936 Attachment 33937 Attachment 33938 Attachment 33939 Attachment 33936 Attachment 33941 ---AutoMerged DoublePost--- Eura tank mounted, brake lines all cut a spliced. Tomorrow cut and shorten the wiring harness. Attachment 33942 Attachment 33943 Attachment 33944 Attachment 33945 |
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Wiring shortened up, drive shaft shortened and put back on, DPF kind of in place.
Attachment 33879 Attachment 33880 Attachment 33881 Attachment 33882 Attachment 33883 Attachment 33884 Attachment 33885 Attachment 33886 ---AutoMerged DoublePost--- Got all the exhaust reconfigured and hung. All the wiring figured out. Last to do is plumb the fuel lines and drill one hole for the new shocks. Attachment 33887 Attachment 33888 Attachment 33889 Attachment 33890 Attachment 33891 Attachment 33892 |
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Got the shocks installed, broke out the bottom of the tank for the sending unit out of the 12. Need to lengthen the sending unit hoses and rods. So the gauge reads right. Also started lengthening the fuel lines.
Attachment 33821 Attachment 33822 Attachment 33823 Attachment 33824 Attachment 33825 Attachment 33826 Attachment 33827 ---AutoMerged DoublePost--- Fuel sending unit lengthened and installed, fuel lines all ran and hocked up, took the hitch back off and sanded and painted it with industrial paint. Fuel tank has to come back down to put the hitch back on because you can't get your hands in the frame to position the nuts/keepers for the hitch bolts and you defiantly can't do it when the body's on. Monday straighten up the wires and fuel lines, take the tank back down put up the hitch, reinstall the tank and transfer the fuel from the 12 into the Ex, fire her up and driver off the frame rack and set the body on the frame. Attachment 33828 Attachment 33829 Attachment 33830 Attachment 33831 Attachment 33832 Attachment 33833 Attachment 33834 Attachment 33835 ---AutoMerged DoublePost--- |
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Everything all tided up. Used the V10 pump to transfer the Diesel from the 12 tank to the ex tank, swapped the filler necks and tubes. Got the 12 Excursion running today. Tomorrow but on the body and do the parking brake.
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Body back on, doors back on, body jigged in and weld in place, Tomorrow welder up.
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Not much to say today. Welded the floor and inner and out rockers together.
Attachment 33654 Attachment 33655 Attachment 33656 Attachment 33657 ---AutoMerged DoublePost--- Made a little more room in the shop today, welded up the A pillars and ground down the welds. Tomorrow prime welds and caulk joints. Attachment 33658 Attachment 33659 Attachment 33660 Attachment 33661 Attachment 33662 Attachment 33663 Attachment 33664 Attachment 33665 Attachment 33666 |
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Got everything epoxy painted. Next week to work on welding the frames together.
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Still working on wiring. Got most of the Ex wiring wired back into the 12. Just have rear wiper, 12v outlet on one side, power for the rear heater/ac fan. Mounted the extra fuse box for those items and all the add accessories. All the DVD players, back up lights, will be coming from the fuse box. It has a hot lead right from the battery 125 amps, and grounding lead to the body and spots to hook up grounds. It's mound underneath the dash right next to where the wiring harness leaves threw the fire wall.
Attachment 33566 Attachment 33567 Attachment 33568 Attachment 33569 Attachment 33570 Attachment 33571 ---AutoMerged DoublePost--- Took my extra fuse box back out so I could split the fuse in half. So I have 6 hot at all times and 6 with hot in the key on position. Had to do this with a relay. I also wired in some more stuff. Back of fuse panel opened up. Attachment 33572 Attachment 33573 |
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Still working on interior wiring. Today I wired the dvd players, one in the drivers head rest, one the passenger headrest and one roof mounted for the third row. They all have to be able to watch the same movie from the big DVD. Also wired for dual usb charging ports. One for the front seats, one for the second seats, one on each side of the third row seat and one in back by 12v outlet. All wired together on one circuit. Put the speakers in from the 12 and wired them. Tomorrow run all the wiring for the 6 seat heaters for the second and third row.
12 on top Attachment 33524 Attachment 33525 Attachment 33526 Attachment 33527 Attachment 33528 Attachment 33529 Attachment 33530 Attachment 33531 Attachment 33532 ---AutoMerged DoublePost--- Pretty much all wrapped up with the interior wiring. Wired the heated seats and started cleaning all the wire mess up. Set heaters wires Attachment 33533 Attachment 33534 Attachment 33535 Attachment 33536 Attachment 33537 |
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Wiring all cleaned up and wrapped up. Time to start on painting the body.
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It's been a hell of a couple weeks been sick quite a bit and busy with costumer work. Getting sick again.
Pulled the rook rack, body moldings and sanded the roof. Attachment 33329 Attachment 33330 Attachment 33331 Attachment 33332 Attachment 33333 Attachment 33334 Attachment 33335 Attachment 33336 Attachment 33337 Attachment 33338 |
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Been crazy busy in the shop for the last couple weeks. Worked on the truck yesterday. Sandblasted all the rust spots.
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More sanding a prepping.
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Jammed the doors today.
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More prep. Painting the roof tomorrow!
Attachment 33066 Attachment 33067 Attachment 33068 ---AutoMerged DoublePost--- Roof painted and body work done. Before Attachment 33069 Attachment 33070 Adhesion Prompter Attachment 33071 Base Coat Attachment 33072 Attachment 33073 Two Coats of Clear. Attachment 33074 Attachment 33075 Body work Attachment 33076 Attachment 33077 Attachment 33078 |
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Door jams painted. Time to hang all the panels and get this thing paint. 2nd and 3rd row seats going to get reupholstered next week.
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Doors and hatch back on all latches back together. Hope to paint the whole truck on Thursday. Picked up a third seat from a 2000 Expedition $50.
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Ready for paint. Painting in the AM. Painted the lower pinch weld like the F250 was.
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This is great work! I love it!
We have been looking for a "newer" Excursion for my wife... I really like this. Can I ask, what kind of money has the customer invested in this? I would be a couple years out, but this may be something to seriously consider... |
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Truck is painted and yes I removed the badges.
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All buffed and shiny. Windshield in. Back glass and doors back together the beginning part of next week.
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So, what kind of pricing is involved here? I am extremely interested, PM me if you'd prefer
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Sprayed tinted the third brake light, installed LED bulbs in the third brake light, bought new LED tail lights, installed the roof rack, started molding the rear fender flares.
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That looks great! Are you going to trim that rear fender flare, or do you have another plan to clear the door?
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Originally Posted by USMC1188
(Post 1058173)
That looks great! Are you going to trim that rear fender flare, or do you have another plan to clear the door?
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Awesome! That is the way to do it lol. Could you cut the flare and then put the smaller cut piece on the door to still give it the flow of the flare?
Thanks for the email. As I said, we are a couple years out, but I really like the work you have done, so this may be the route we go. |
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