This page will highlight our V4 build from start to finish. This is a big project, so sit back enjoy the endless work!
V4 started life as an ambulance in GA. I picked it up out of a scrap yard in December 2011 after months of looking for the right donor. It met all of my criteria. 7.3, clean dash, no rust. The frame was in amazing shape, perfect for this project. V4 just went thru a major rebuild/refresh in 2014 so here are the current specs:
2002 E350 7.3 12" cab back extension UJOR 8" conversion with modified fenders to clear 38" tires Stage 2 UJOR Dana 60 w/RSC upgrade Sterling 10.5" rear w/Yukon Grizzly Locker Toyo MT 38/13.50/20 Robby Gordon wheels 20x10 UJOR Onboard Air System w/5 gallon tank sPOD power system Warn 16.5 Winch UJOR Aluminum Front Bumper Rigid Industries 30" Combo bar UJOR custom main fuel tank, 55 gallon capacity, UJOR custom aux tank, 30 gallons UJOR DS001 Front dual shock mounts with Bilstein 5160 series shocks Diamond Eye 4" exhaust system Hood Lovers Toolman designs overhead console Auto Meter gauges (HPOP, EGT, Tranny Temp) DP Tuner cusotm engine tuner Mag Hytec Transmission Pan Dynatrac Differential Covers UJOR Rear Airbag Overload system UJOR Custom Aluminum flat bed Rhino Lining bedliner on bed and rockers Rigid Industries custom LED tail/reverse lights Ford reman 7.3 w/fuel bowl delete
V4 @ The Flats. Marion NC
V4 before I bought it.
By the time I decided to purchase it, the rear axle had been sold as well as a few other parts under the hood. On day 1 I installed a Sterling 10.5 so we could roll it around.
Teardowns are always fun! Pulling the body makes everything SOOOO much easier, especially since I planned to re seal the engine. We addressed all of the common 7.3 oil leak problem areas with a complete o-ring kit. Pulled the injectors, everything! New glow plugs, valve cover wiring harness, HPOP oil lines, and a good cleaning of the valley.
After we stripped everything from the body, we fabbed up a dolly for the cab to ride on. Easy to move around now! The body is currently at the body shop receiving the 12" can back and a full paint job.
The frame was completely wire wheeled, cleaned & painted next. Since V4 is getting the DS001 dual shock kit, this was the time to do all of the cutting & welding. Front & rear springs, axles, crossmember trimming, the whole 9 yards.
And here it is outside, lift installed, ready for the body to return. There's still plenty of work to do, but V4 will be idle while we build some other vans.
Time to build a bed! To do so, we picked up the in progress body from the body shop so we could get the dimensions we need. We had some 37" BFG's at the shop for another project which so we threw them on the chassis too. Lookin good but so much work left!
The bed is all aluminum with 2x4's outside and 2x2 supports. The bed is using a 3 mount design that pivots in the rear so nothing is in a bind when things get twisty. The front & rear boxes are full pass thru, lots of storage! All of the boxes are constructed from 3/16 aluminum plate.
View from the rear of the front box. These storage boxes are huge and go all the way across!
LOTS of work to get to this point. The boxes are all 3/16 aluminum diamond plate as well as the top. All exterior welds were done with a Tig welder, interior was done by a spool gun. This bed turned out beautiful!
Here is the bed after it was coated with Rhino Lining. This is a good view of the aux fuel tank, 32 gallons. We have a transfer pump mounted to the bed that sends fuel to the main tank and the bed also holds the ARB air compressor and air tank.
The body back from paint! We went with a factory Ford green, very happy with it.
The guys at Smokeys Rod & Custom did a great job.
Front suspension coming together! Great view of the Bilstein 5160 series shocks and the Dynalock hubs. These hubs are a work of art, heavy duty.
Sterling 10.5 is ready for install. This bad boy is packing an ARB Air Locker and its sealed up with a Dynatrac diff cover. UJOR SA001 Sterling install kit with brake lines.
Everyone knows that if you want to cool the transmission down the best way is to add a Mag-Hytec transmision pan! Another beautiful piece of machined aluminum. They add 7 qts of capacity and I also installed an aux cooler with a fan.
Starting to come together!
Bed installed! This is a good view of the rear pivot. When the chassis flexes, the bed and camper aren't in a bind. Here you can also see the rear Rigid lights.
We udated the front end to the 04-07 front grille and head/turn lights, added the UJOR Aluminum front bumper, Warn 16.5 winch and the Rigid 30" light bar.
Hood vents turned out really nice. I added some black rivets to finish them off.
Rear suspension showing the UJOR floating rear airbag system while it was being installed. Good view of the fuel tank fills too.
After a few crazy long days, it was time to hit the road. We were a bit crazy to drive something like this all the way across the country with the amount of work we did, but we had deadlines to meet! This pic was taken in KS at a rest stop on day 2.
Just east of Denver we hit a crazy snowstorm. Could barely see 2' in front of the rig, scary stuff! Made it to Denver for some rest.
Made it to Grass Valley CA, the home of XP Camper! We joined their crew for a few days to finish up the camper, got it bolted down, then bolted for Vegas to make our load in time @ SEMA.
We made it! Setup right before dark, felt good to make it to the big show.
Gotta show the love for all of the sponsors! Big thanks to everyone that helped out.
After the show we headed for the hills! The Alabama hills in CA. We then continued north to the Mammoth Lakes area to relax and camp. The XP is great! Super comfortable and my pregnant wife loves the bathroom :)