Ultra Family and Hauler Mobile
 

I purchased this from a board member and this is going to be my wife's daily driver and the vehicle we take on trips. We have 2 kids right now and a third on the way. So, an Excursion with 3rd row seating seems logical. :lol: This was a V10 auto truck and has 4:30 gears. My plan was to take the VE 24V from my 76 Chevy and put in this. More on that later. So, I want this done sooner than later and I decided to buy engine mounts. This was the first time I have done this on a conversion of my own. I called up Auto World and talked to my lady friend Dawna. She got them to me in 3 days!

Last weekend my brothers moved trucks around and on Monday morning last week we put the Excursion in the shop. I installed the Auto World engine mounts, and then set the engine in the truck. Tuesday I finished installing the engine in the frame, and put my tach tone ring on. I then decided to see if the engine would turn over since it's been sitting for a while since I rebuilt it. Son, of, a B****. That was a big no............. Now what? I gave thought to putting a 12v in it but the only one I have is saved for the 72 project of my brothers. Luckily I have 1 more 24v complete without fuel system. It has high miles but ran good and didn't smoke. So on Thursday we moved stuff around and got the other 24v in the shop. We also tore apart the old engine. Water got in it and #6 cylinder was rusted pretty bad. I tried cleaning it and honing it, but it's too bad. When we pulled the pan there was water in there and the crank and rods are really rusty. The cam is really rusty too. Nick and I got the engine broke loose too. It's really weird, the cam and crank gears had hardly any rust on them. The injection pump gear was really rusty though. Must be the different mixture in the metals? IDK

So right now I'm in the process of swapping the new 24v over to a VE. The injection pump is at the pump shop. They're waiting for a 3200 gov spring, and I'm going to order a Denny T Stage 2 fuel pin. I'm hoping to have the engine in the truck by the end of the week and get cracking on it. I have 4" exhaust and an aero tirbine muffler for it, a rebuilt 47RH, a single disc billet torque converter, and a rebuilt 241DHD small out put for it. I'll be using a Procomp black pump for a lift pump with a 24v filter head for fuel/water filter. I'm going to put 3:55s in the rear end for now. I'm hunting for a D60 for the front, but in a hurry. I need to get it going and then reccop some funds before I get to that point. Here are some pics.

http://i181.photobucket.com/albums/x...509_113922.jpg
http://i181.photobucket.com/albums/x...509_113943.jpg
http://i181.photobucket.com/albums/x...509_113959.jpg
http://i181.photobucket.com/albums/x...506_113206.jpg
http://i181.photobucket.com/albums/x...506_120135.jpg
http://i181.photobucket.com/albums/x...506_113218.jpg
http://i181.photobucket.com/albums/x...506_120151.jpg
http://i181.photobucket.com/albums/x...509_113750.jpg
http://i181.photobucket.com/albums/x...509_113738.jpg

Re: Ultra Family and Hauler Mobile
 

I so admire guys like you, I would be so apprehensive to even buy that truck let alone put a diesel motor in it. The Ex really looks nice too. was the old motor blown or?

Re: Ultra Family and Hauler Mobile
 

Thanks Clyde. The engine was removed for another truck before I got it. The way this got to where it's at is; Either the front drive shaft cardinal joint locked up, or the transfer case bound up. The front drive shaft broke the transfer case in half, then proceeded to break the trans case, and whopped the frame putting a goudge in the upper frame flange, which set off the air bags and broke the windshield. The guy I got it from purchased it from the owner. Kind of weird the guy sold it as he was a Ford Service Tech. Oh well, works great for me.

Re: Ultra Family and Hauler Mobile
 

Today I didn't get much done on it. I did hook up the battery and test the blower motors, rear window vents, front and rear windows, power locks, and I got the radio working too. This thing even has a 6 disc CD changer, and it had 5 free CD's in it, and the changer works. Sweet! :lol:

Re: Ultra Family and Hauler Mobile
 

Any good CDs? Ha ha.

I looked at buying a 7.3L Excursion but they're kinda hard to find and cost too much for what you get. We ended up getting a suburban, but really wish we would have stuck with the crew cab 1/2 ton we had....oh well....guess that's why I ended up building my '97.

Re: Ultra Family and Hauler Mobile
 

Aerosmith was about the best one I saw. :lol: Crew cabs are nice, but are hard to fit 3 car seats and 2 adults plus any groceries if your bed is open. :lol:

Re: Ultra Family and Hauler Mobile
 

Been looking forward to this build man. Maybe Ill get to see it in a month and a half!

Re: Ultra Family and Hauler Mobile
 

I have been wating to see this as well. Looks like a sweet project. You sure found just the rite truck to start with . How do you think the 24V Rotary pump motor will work ? Have you done this before ? Where did you get the custom inj lines ? Keep up the great work.

Re: Ultra Family and Hauler Mobile
 

Yeah you will. We had better be driving it around by then. For real. :lol:

I think it'll be great. Nope, this is the first one I've done. More air flow than a stock VE 12v which will go along with the extra fuel added from the fuel pin and turning up the pump. Once I get it timed where I want it, it should be fine. Cheaper swap than a P-pump, and more reliable too. I had the lines bent at Scheid Diesel. Too bad they didn't use coated lines to start with. Because now they are rusty. They surprisingly fit better than the P-pump lines they do. Not real happy about any of the P-pump conversion lines we've gotten the last year and a half................

Re: Ultra Family and Hauler Mobile
 

Congrats on the 3rd! How far along are you? We are at 31 weeks with our 3rd... Excursions are the only SD I like. Please tell me you are keeping the pre-07 front end on it.

Re: Ultra Family and Hauler Mobile
 

Thanks! I believe she is at 32 weeks. I've got to get this thing running soon. :lol:

Yes, I'm keeping the original grill and bumper. I'm thinking about putting 07 clear style head lights in it though. I'm not sure how it'd look with the HD ones on it.

Re: Ultra Family and Hauler Mobile
 

I've seen your dead lines fly by in no time before. Maybe this will be different. :lol:
Posted via Mobile Device

Re: Ultra Family and Hauler Mobile
 

I just have 2 kiddos, so they fit in the CC no problem....we're going to call it quits on the kiddo production :P we don't want to be outnumbered.

Re: Ultra Family and Hauler Mobile
 

:lol:

Re: Ultra Family and Hauler Mobile
 

Me too . I've been sleeping face down ever since our 2nd showed up :lol:

Re: Ultra Family and Hauler Mobile
 

24V VE pump Excursion?? I'm in.

sorry I haven't called. Been trying to get the crawler done for this weekend. I'll give you a shout after the holiday

Re: Ultra Family and Hauler Mobile
 

Been busy working on this thing, trying to locate parts and get a move on. Last weekend we got the engine put back together. I got the injection pump back and installed it as well. I painted the engine Saturday night and worked on odds and ends on the engine Sunday.

http://i181.photobucket.com/albums/x...8_205059_1.jpg
http://i181.photobucket.com/albums/x...518_205111.jpg

Sunday we had big storms coming all afternoon. Guess what? My wife finds out we have to pick up some furniture from her Grandmother's home and it had to be out by the end of the night. We rounded up my buddy Spencer and my brothers and we went furniture hauling. We get there and everything still has stuff in it. We were going through the garage with my sister in law and Spencer asked about the pop machine burried in the back. Long story short, we struck a deal on it. We sent Nick and scott to go borrow a small trailer so we could bring it home. While they did that I helped my wife remove stuff from a hutch and a cedar chest. I get the stuff loaded up and Spencer shows me his radar on his phone. He says, "Buddy, I haven't seen Purple on there in a long time!" :lol: We look to the NW and holly chit fire! About that time Nick gets there. We move vehicles, back the trailer in and proceed to move this pop machine. I tell you what, that SOB should be a safe! It's hella heavy! We get it loaded up and it begins to rain. We jet, and of course we get stuck behind some slow goers...... We stopped at my place to unload our furniture, then went to the shop to unload the safe. :lol: We get it inside and then I go over to start shutting the shop up. I got things ready before we left to put the engine in the Excursion. I finished jacking the engine hoist and we were starting to push the Ex into the hoist. My daughter decided she was going to help push Mom's truck.

http://i181.photobucket.com/albums/x...519_185837.jpg

We pushed it forward and fought the engine in the engine bay. These really need to go in with no valve cover, but I didn't want to get debris in the engine, and we were trying to beat the storm!

http://i181.photobucket.com/albums/x...519_191606.jpg
http://i181.photobucket.com/albums/x...519_191616.jpg

We leave and start heading home and my wife stops at Caseys. I was like WTF. It's now pouring and blowing 60mph+. She needed gas, she was almost out! I was following her in the truck, so I ran over to stay with the kids while she went in to get milk. While she's in there i'm watching the awning watching it sway. I was about ready to move the car and she finally came out. We go to leave and she circles and parks under the awning again. I'm really getting peeved now. I drive back around and remembered her wipers are inop. SOB! :lol: I made her switch vehicles with me and then I drive home with no wipers, no glasses, and a fogged over windshild because the heater core is leaking. We made it home safe but were drowned like rats!

Re: Ultra Family and Hauler Mobile
 

Monday I dug the transmission out that I got from the Colorado Kid, AKA RyanRoo. Thanks buddy! It's a 47RH that was rebuilt by Phoenix trans. I put my DPC single disc billet torque converter in it, installed the gear selector arm and throttle pressure arm, and Nick and I stuck it in. We then bolted the transmission cross member in and it was time to go to work.

http://i181.photobucket.com/albums/x...520_103942.jpg
http://i181.photobucket.com/albums/x...0_103931_1.jpg

Wednesday I didn't have any of my parts so I didn't get much done to it. I installed my new LH battery tray, and cleaned the A/c comp. Wednesday night my brother Scott crawled out from under his rock and removed the axles and carrier. He also dropped the 42gal tank that is 3/4 full of that nasty gas crap. :lol:

http://i181.photobucket.com/albums/x...521_120551.jpg

This morning I got the transmission mount half done, got the fan and belt on for test fitting, installed the temp sender and oil pressure sender, and finally got a turbo to fit in there.

http://i181.photobucket.com/albums/x...3_124428_1.jpg
http://i181.photobucket.com/albums/x...523_124514.jpg

I'm going to keep going on it and would love to have it running by end of next weekend. We'll see if the rest of the little odds and ends show up. There's still a lot to figure out and get finished.

Re: Ultra Family and Hauler Mobile
 

Sounds like a fun story man. What I would give for rain again! I hope you can keep the momentum up on this build. Momma's truck always comes first here too.

Re: Ultra Family and Hauler Mobile
 

I am looking forward to seeing this one complete. I think Excursions are cool, and you are making this one better.

Re: Ultra Family and Hauler Mobile
 

This thing is sweet! i fully expect to see it in CO sometime! i really like that color and have always had a bit of a thing for the excursions. they just look better than the trucks with the SD body lines. now get that sucka done so the little lady will leave you alone to finish the Longhorn.

i had another body guy come out and give mine the once over for a estimate. said we should be able to get color on the cab and clip by the 4th of july. might even want to do some horse trading for my other K20! ill catch up one way or another!

Re: Ultra Family and Hauler Mobile
 

oh, i just found a Ex being parted on the denver CL. says 373 front axle... i assume that means 3.55 and the dude is a tard....

just sayin

Re: Ultra Family and Hauler Mobile
 

Nah, it's prolly 3.73. They quit 3.55 with the old body style and now only have 3.73, 4.10, and 4.30. Pretty dumb if you ask me. Was it a D60 front?

Re: Ultra Family and Hauler Mobile
 

That would be awesome! There would be hope for The mountain event huh? :devil:

Re: Ultra Family and Hauler Mobile
 

Sub'd for the rest of the build.

I saw this one a while back, not sure if you've seen it yet. There's probably a hand full of them out there.

Re: Ultra Family and Hauler Mobile
 

Yeah, I saw it a while back and was like dang, he got his running before me. :lol: The truck was for sale on ebay when I saw it.

Re: Ultra Family and Hauler Mobile
 

looks like im the tard....

didnt say. i was just skimming over the listings. i forget what i was searching for.

Re: Ultra Family and Hauler Mobile
 

No you're not a tard, it's just Ford's lovely way. :lol:

Re: Ultra Family and Hauler Mobile
 

a few pics of the ryanroo method on fan shrouds

http://i94.photobucket.com/albums/l8...15/m715403.jpg

http://i94.photobucket.com/albums/l8...15/m715398.jpg

http://i94.photobucket.com/albums/l8...15/m715399.jpg

the one on my truck will be similar, but i think i will build it so it splits in the middle to make the fan easier to remove. this one on the jeep is a major pain witht he low clearance between the fan and core

Re: Ultra Family and Hauler Mobile
 

it works like a charm though! walk to close to the jeep while its running and that thing will suck off your shirt. not good if you are in crowd of females. they swarm a fella. learned that the hard way....

:lol:

Re: Ultra Family and Hauler Mobile
 

1. Never had that problem... any scars from it?:lol:
2. Is that Aluminum?
3. Is that a BBC?
4. Why do you still have an AIR pump on it?
5. Are you going to build one for Ryan's wife's family mobile as a baby shower present?

Re: Ultra Family and Hauler Mobile
 

Is that a Kaiser with a BBC? 454?

Re: Ultra Family and Hauler Mobile
 

only a few scars!

yes

yes (of course)

air pump is long gone now! its also TBI now

well, id have to have some plans before i could even think about it. he wants some black plastic thing though, said it looks better than hack welds...


yessir

http://i94.photobucket.com/albums/l8...5/100_1078.jpg

Re: Ultra Family and Hauler Mobile
 

Hey Ryan, there us an 01 diesel 4x4 Excubus here in town getting parted out. You want me to ask about any of it?
Posted via Mobile Device

Re: Ultra Family and Hauler Mobile
 

Sure, check to see if it's a limited by chance. I'd like to get the woodgrain inserts from the door panels and console. Thanks for keeping me in mind.

Re: Ultra Family and Hauler Mobile
 

That's complete BS! :lol:

Re: Ultra Family and Hauler Mobile
 

Ok, time for some updating to this thread. While Ryanroo's fan shroud is awesome, I don't have the means to weld aluminum right now. So I opted for a more factory appearing method which I could complete. I cut the factory V10 fan shroud, and another donor shroud, and built a new to it shroud by plastic welding it all together. It isn't perfect, but I can't spend a lot of time making it perfect as I need to get this thing running ASAP.

Upper radiator hose modified and installed.

http://i181.photobucket.com/albums/x...527_150512.jpg

Fan Shroud Building

http://i181.photobucket.com/albums/x...530_172151.jpg
http://i181.photobucket.com/albums/x...531_180736.jpg
http://i181.photobucket.com/albums/x...531_180752.jpg
http://i181.photobucket.com/albums/x...531_180803.jpg

Once I got the fan shroud finished, I moved on to building the lower water inlet. I didn't want 6 different hoses and 12 hose clamps, so I built this pipe and it will use a 90* hose up top and a straight hose on the bottom.

http://i181.photobucket.com/albums/x...601_111401.jpg
http://i181.photobucket.com/albums/x...601_111343.jpg
http://i181.photobucket.com/albums/x...601_120256.jpg

Next I moved on to the down pipe. I wasn't happy with how the S300 compressor cover sat on the exhaust manifold, or darn near it. The waste gate was also really close to the HVAC box. So I drilled the holes out on a T3 spacer I aquired from my friend Ryanroo. Thanks buddy! Next I used some 4" 90* pipe bends and an expensive HX40 outlet flange, and built the down pipe.

http://i181.photobucket.com/albums/x...601_191423.jpg
http://i181.photobucket.com/albums/x...601_191452.jpg

I also got my power steering lines modified and installed. I got the 3:55 ring gear installed on the 4:30 carrier, ran the exhaust, installed the oil presser sender and the coolant temp sensor, installed the Tcase, ran the tranny cooler lines and hooked them up, and cleaned and painted the fan shroud.

The next jobs to do are:

Install new to it pinion and set up rear diff

Remove yoke from dodge donor rear drive shaft and install on tcase and measure for new rear shaft

Get exhaust hangers and install them, then install exhaust clamps, paint down pipe

Clean fuel tank and install pick up tube

Run fuel lines and install fuel filter housing

Build throttle bracket and reposition speed control unit

Modify the ford engine harness and eliminate un needed wiring

Rebuild turbo, paint exhaust manifold, drill for pyro

Install Pyro, Boost, and trans temp gauges

Add fluids, flush cooling system before fill up, plug in block heater and retorque head bolts before fire up, then recheck the over head

Figure out a/c lines and get them going, purchase new receiver/drier,

Finish grind CAC tubes and paint them, install a/c condensor and new a/c comp

Build Air Filter Inlet Pipe

Purchase Voltage Reg and install it

Hopefully this list can get smaller soon. :lol:

Re: Ultra Family and Hauler Mobile
 

This thing is going pretty fast man! Keep up the work.
Posted via Mobile Device

Re: Ultra Family and Hauler Mobile
 

looking good!

Re: Ultra Family and Hauler Mobile
 

I've been trying to get odds and ends on this thing. Ordered a new throttle cable for it, got my yoke robbed from a dodge drive shaft, installed the tcase rear out put shaft seal, installed yoke and measured the shaft length. Took the shaft to the drive line shop yesterday, and they got it done today. Yesterday my dad installed the 3:55's in the rear axle and got it set up. Now I'm trying to arrange the fuel filter location so I can get the throttle bracket built and on. Little by little..............