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So my 93 Ford E250 Sportsmobile project is coming along nicely, but there is still a LOT of work that needs done, particularly metal and wood work...
Done so far / recently.
- Replaced water pump, radiator, upper and lower radiator and heater hoses, and of course all new stainless steel clamps.
- Replaced power steering pump and lines.
- Rebuilt the brakes including new calipers on the front.
- Rebuild the rear end (just prior to my ownership).
- Rebuild the chassis air conditioning. New compressor, lines, flush out evaporator and condenser, convert to R134A previously done.
- Replace Belt tensioner. This engine does not have an idler pulley.
- Replace OEM alternator (80 amp) with a high output RV 140 amp alternator.
- Removed battery isolator / lead acid coach battery and pan for lead acid battery. The isolator is still there, I need to get into a VERY tight spot and get an EZ out into a stripped screw head, but it is out of the circuit.
- Installed 400 amp hour Lithium Iron Phosphate smart battery.
- Installed 40 amp DC to DC Lifepo4 compatible charger with MPPT solar charge controller.
- Installed 55 amp 110v AC to 12v DC converter charger.
- Created and installed pass through port for solar where lead acid battery vent was in the side of the van.
- Created custom parallel input cable to go from the dual SAE to a single 50 amp Anderson connector to input from my...
- Carried over the 2 300w 18v solar panels from the truck camper project. That project has taken a back seat for now.
- Created custom 12v DC and USB fast charging panel, 3 dual USB charging ports and 3 12v sockets, independent on / off switches for the USB and the 12v power port sections. Not yet installed in camper but must be within the next 2 weeks...
- Replaced broken light fixture with LED, don't like it, looking for a different style.
- Replaced all interior bulbs possible with LED.
- Replaced all exterior light assemblies as they were all cracked, with new units, converted all bulbs to LEDs.
- Removed undercarriage spare tire carrier per Ford and Sportsmobile guildelines this required...
- Addition of Class IV reciever hitch that acts as rear most frame cross member.
- Replaced the full exhaust excluding the catalytic converter which wasn't bad... New exhaust manifolds, new collector pipe, new cat back shortened to side dump in front of the rear tire. The manifolds were cracked and the original muffler had a fist sized rust hole in it, I needed space behind the axle for water tanks so out the side it went. The shop messed up and went with an OEM style muffler, I wanted a Flowmaster 40 on there to allow for a bit more power as the 150hp of the straight six is a bit pitiful.
- Tune up. Cap, Rotor, plugs, wires, injection cleaning service, and a healthy dose of SeaFoam to the last 2 tank fills. (35 gallon tank, I ran it to almost fully dry and am deep cleaning, so literally used half a gallon per fill up...)
- New fuel pump module. Original was in the process of failing.
- While the fuel tank was out, installed dip tube, hoses, wiring, pump etc.. and isntalled gasoline furnace. Same sort of thing as the Chinese Diesel heaters but MUCH higher quality, actual Thermostat control, and runs off of my gas fuel tank.
- New multifunction switch, Turn signals, wiper controls etc...
- New dash lights.
- Fix 12v / lighter socket on the dash.
- Install modern CB radio with AM/SSB/FM and weather.
- Install and fine tune 102" stainless steel whip antenna. I am hard to miss in a parking lot.
- Sewed new custom blackout curtain for sliding cargo door window.
- Using Durhams Rock Hard reinforced endges of MDF on the cabinet edges, dowel drill and fill for the screw holes for the hinges. Reattached cabinet doors.
- Replaced the 30 year old Porta Potti with a new SeaFlow premium toilet.
- Installed added USB power outlet in rear panel, added CMYK LED strip lighting the the edge of the ceiling on the lower part of the van. Upper pending replacing the fixtures there with LEDs as well...
- Installed back door spare tire carrier, had to modify it because the models sold to fit the Econolines are NOT fitted to the 16" 8 lug wheels of the 3/4 and 1 ton models. Had to drill custom holes to get the spacing right...
- Ordered custom spare tire cover with my youtube channel logo / branding, currently en route.
- Replaced all 5 dry rotted tires with new Venom Power Terra Hunter X/T upsized to 245/70 R16. Not huge, but effectively 30.9x10" which is good enough for beach camping in TX...
- Added Rainblades, which are like the vent shades you see on drivers and passengers doors, but keep rain out of the RV section sliding windows.
- Added vent shades to front door windows.
- Replaced the 31 year old factory speakers with new Infinity Reference series speakers. Head unit / infotainment system pending... This will include backup camera, and dash cam function, GPS, and streaming functions.
- Replaced the cracked plastic grille with a new metal slat style grille for that 90s vibe...
- Serviced the bungee cord retractor for the canvas top.
- Created angle iron cross braces to secure the base of the bed when in bed mode and not in dinette mode... I am big / heavy and worry about support...
- Replaced the 110v dorm fridge that would not work unless I was plugged into shore power or running off of a generator / inverter, with a 12v RV fridge.
- Trimmed, laminated, and mounted to my pantry door a "Living In A Van Gogh Down By The River" poster as a funny decor item.
- Designed, 3D printed, and installed wall mount bracket for my ResMed Air Mini CPAP machine.
- Cleaned up my hitch hauler, added reflective DOT safety tape to it. Added a lockable weather resistant, cut resistant cargo bag fitted to the hitch hauler.
- Added a 4" Memory foam mattress topper, almost a mattress of its own.
My pending repairs / upgrades are no slouch either.
- Finish implementing jobs listed above. Install the power panel, install the infotainment system / camera system etc..
- Redesign / build of new kitchen cabinet / countertop. I HATE the layout of the factory unit, there is no good way to integrate the sink, the original was on a hinged top with bad storage layout. Building a Maple / Pecan butcher block countertop, and flip up tables.
- Install sink with flip down faucet and tempered glass lid.
- With the help of a welder friend, design, and build frames for the 25 gallon fresh water, and 20 gallon gray water tanks. Install and plumb tanks.
- Obtain replacement coach AC compressor. This is unfortunately a 110v unit, I am looking for a compatible 12v unit so I can run fully off grid.
- Get the muffler screw up fixed. Go with a 2.5" cat back (already there) and Flowmaster 40 series SI/SO muffler.
- Working with Comp Cams on this one, but looking for the right profile cam to bump up HP a bit, but more importantly torque, while keeping the ability to run on 87 octane as I tend to travel where fuel selection stinks...
- Once available from the builder, get a set of the rain gutter Z clamps for adding a passengers side awning, and add a knock off ARB style awning 8' 2" x 8' 2".
- When funds become available, body rust repair / fix some bad rust repair. Pop top vans tend to hold water against the rain gutters causing rust. Mine need to be done.
- 4wd conversion with new transmission. This is going to take a while and will require new wheels / tires, spare tire carrier assembly / rear bumper.
- Repaint with tinted Raptor Liner, 2 tone in upper tan, lower, bumpers and grille dark brown.
- Install LED Off Road light pods on the hood. Pending some new cowl mount brackets from a Canadian vendor once they ramp up production.
- Add a mattress topper for the penthouse (upper) bed...
The interior cabinets are funny, they seem to bolt together using steel brackets, so my plan is to replace the panels using the originals as templates, redesigning what I need to as I go...
Done so far / recently.
- Replaced water pump, radiator, upper and lower radiator and heater hoses, and of course all new stainless steel clamps.
- Replaced power steering pump and lines.
- Rebuilt the brakes including new calipers on the front.
- Rebuild the rear end (just prior to my ownership).
- Rebuild the chassis air conditioning. New compressor, lines, flush out evaporator and condenser, convert to R134A previously done.
- Replace Belt tensioner. This engine does not have an idler pulley.
- Replace OEM alternator (80 amp) with a high output RV 140 amp alternator.
- Removed battery isolator / lead acid coach battery and pan for lead acid battery. The isolator is still there, I need to get into a VERY tight spot and get an EZ out into a stripped screw head, but it is out of the circuit.
- Installed 400 amp hour Lithium Iron Phosphate smart battery.
- Installed 40 amp DC to DC Lifepo4 compatible charger with MPPT solar charge controller.
- Installed 55 amp 110v AC to 12v DC converter charger.
- Created and installed pass through port for solar where lead acid battery vent was in the side of the van.
- Created custom parallel input cable to go from the dual SAE to a single 50 amp Anderson connector to input from my...
- Carried over the 2 300w 18v solar panels from the truck camper project. That project has taken a back seat for now.
- Created custom 12v DC and USB fast charging panel, 3 dual USB charging ports and 3 12v sockets, independent on / off switches for the USB and the 12v power port sections. Not yet installed in camper but must be within the next 2 weeks...
- Replaced broken light fixture with LED, don't like it, looking for a different style.
- Replaced all interior bulbs possible with LED.
- Replaced all exterior light assemblies as they were all cracked, with new units, converted all bulbs to LEDs.
- Removed undercarriage spare tire carrier per Ford and Sportsmobile guildelines this required...
- Addition of Class IV reciever hitch that acts as rear most frame cross member.
- Replaced the full exhaust excluding the catalytic converter which wasn't bad... New exhaust manifolds, new collector pipe, new cat back shortened to side dump in front of the rear tire. The manifolds were cracked and the original muffler had a fist sized rust hole in it, I needed space behind the axle for water tanks so out the side it went. The shop messed up and went with an OEM style muffler, I wanted a Flowmaster 40 on there to allow for a bit more power as the 150hp of the straight six is a bit pitiful.
- Tune up. Cap, Rotor, plugs, wires, injection cleaning service, and a healthy dose of SeaFoam to the last 2 tank fills. (35 gallon tank, I ran it to almost fully dry and am deep cleaning, so literally used half a gallon per fill up...)
- New fuel pump module. Original was in the process of failing.
- While the fuel tank was out, installed dip tube, hoses, wiring, pump etc.. and isntalled gasoline furnace. Same sort of thing as the Chinese Diesel heaters but MUCH higher quality, actual Thermostat control, and runs off of my gas fuel tank.
- New multifunction switch, Turn signals, wiper controls etc...
- New dash lights.
- Fix 12v / lighter socket on the dash.
- Install modern CB radio with AM/SSB/FM and weather.
- Install and fine tune 102" stainless steel whip antenna. I am hard to miss in a parking lot.
- Sewed new custom blackout curtain for sliding cargo door window.
- Using Durhams Rock Hard reinforced endges of MDF on the cabinet edges, dowel drill and fill for the screw holes for the hinges. Reattached cabinet doors.
- Replaced the 30 year old Porta Potti with a new SeaFlow premium toilet.
- Installed added USB power outlet in rear panel, added CMYK LED strip lighting the the edge of the ceiling on the lower part of the van. Upper pending replacing the fixtures there with LEDs as well...
- Installed back door spare tire carrier, had to modify it because the models sold to fit the Econolines are NOT fitted to the 16" 8 lug wheels of the 3/4 and 1 ton models. Had to drill custom holes to get the spacing right...
- Ordered custom spare tire cover with my youtube channel logo / branding, currently en route.
- Replaced all 5 dry rotted tires with new Venom Power Terra Hunter X/T upsized to 245/70 R16. Not huge, but effectively 30.9x10" which is good enough for beach camping in TX...
- Added Rainblades, which are like the vent shades you see on drivers and passengers doors, but keep rain out of the RV section sliding windows.
- Added vent shades to front door windows.
- Replaced the 31 year old factory speakers with new Infinity Reference series speakers. Head unit / infotainment system pending... This will include backup camera, and dash cam function, GPS, and streaming functions.
- Replaced the cracked plastic grille with a new metal slat style grille for that 90s vibe...
- Serviced the bungee cord retractor for the canvas top.
- Created angle iron cross braces to secure the base of the bed when in bed mode and not in dinette mode... I am big / heavy and worry about support...
- Replaced the 110v dorm fridge that would not work unless I was plugged into shore power or running off of a generator / inverter, with a 12v RV fridge.
- Trimmed, laminated, and mounted to my pantry door a "Living In A Van Gogh Down By The River" poster as a funny decor item.
- Designed, 3D printed, and installed wall mount bracket for my ResMed Air Mini CPAP machine.
- Cleaned up my hitch hauler, added reflective DOT safety tape to it. Added a lockable weather resistant, cut resistant cargo bag fitted to the hitch hauler.
- Added a 4" Memory foam mattress topper, almost a mattress of its own.
My pending repairs / upgrades are no slouch either.
- Finish implementing jobs listed above. Install the power panel, install the infotainment system / camera system etc..
- Redesign / build of new kitchen cabinet / countertop. I HATE the layout of the factory unit, there is no good way to integrate the sink, the original was on a hinged top with bad storage layout. Building a Maple / Pecan butcher block countertop, and flip up tables.
- Install sink with flip down faucet and tempered glass lid.
- With the help of a welder friend, design, and build frames for the 25 gallon fresh water, and 20 gallon gray water tanks. Install and plumb tanks.
- Obtain replacement coach AC compressor. This is unfortunately a 110v unit, I am looking for a compatible 12v unit so I can run fully off grid.
- Get the muffler screw up fixed. Go with a 2.5" cat back (already there) and Flowmaster 40 series SI/SO muffler.
- Working with Comp Cams on this one, but looking for the right profile cam to bump up HP a bit, but more importantly torque, while keeping the ability to run on 87 octane as I tend to travel where fuel selection stinks...
- Once available from the builder, get a set of the rain gutter Z clamps for adding a passengers side awning, and add a knock off ARB style awning 8' 2" x 8' 2".
- When funds become available, body rust repair / fix some bad rust repair. Pop top vans tend to hold water against the rain gutters causing rust. Mine need to be done.
- 4wd conversion with new transmission. This is going to take a while and will require new wheels / tires, spare tire carrier assembly / rear bumper.
- Repaint with tinted Raptor Liner, 2 tone in upper tan, lower, bumpers and grille dark brown.
- Install LED Off Road light pods on the hood. Pending some new cowl mount brackets from a Canadian vendor once they ramp up production.
- Add a mattress topper for the penthouse (upper) bed...
The interior cabinets are funny, they seem to bolt together using steel brackets, so my plan is to replace the panels using the originals as templates, redesigning what I need to as I go...
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