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Old 09-20-2017, 02:35 PM   #1
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2003 Ford 7.3 PSD 15 passenger build update

It’s been awhile since I posted anything about my build. I've nearly completed my 2003 15 passenger 7.3 van after 8 years. I would never have been able to pull this off without the knowledge gained from these forums and the hundreds (maybe thousands) who blazed the home built van trail before me. Thank you to everyone who has shared their builds, ideas, successes, and failures. My van has helped create countless memories, taken my family up and down the west coast numerous times, desert trips, beach trips, boy scout trips, on and on.

Stage 1 - Summer of 2010 did the UJoint Conversion, took 12 hours using a lift and air tools. Super fun to install, no big surprises. Added aluminess spare tire carrier and ladder, then took a trip to Quadvan to have the sliding door modified to clear the tires.

Stage 2 - Summer 2011 rebuilt and converted the transmission, added transfer case, 4.10 front gears to match rear, ARB locker, shortened fuel tank and custom drive lines.

Stage 3 - Summer 2012 built roof rack, added accessories like running boards, bushwacker flares, Fiamma awning, LED lights, GoLight, and lightforce lights.

For the next 5 years - Countless trips camping, exploring, and just simply making good memories with the wife and 4 boys.

Stage 4 - Summer 2017 self installed MSD top coated in monstaliner, home built harbor freight roof rack, and mostly hand made interior. G-floor, 1/2' baltic birch cabinets with formica overlays, SMEV Sink/Stove, truck fridge, propex, 6 gal water heater, 28 gal fresh water, under floor storage, shop4seats 60" rear fold down bench, 1der seat swivel, Aluminess front bumper, 350 watts flexible solar, Zamp Dual solar charge controller, battleborn 100Ah lithium battery

Enjoy

Luke

First pic is just after purchase, second is just after stage 1, third was trip to quadvan for slider mod, 4th is how it has been for the last 5 years until the latest stage
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001 van.jpg   002 van.jpg   004 van.jpg   003 van.jpg  
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Home Built Camper Van - 2003 EB 15 Passenger, 7.3 PSD, Ujoint 6" Lift, 35x12.50x17E BFG AT2 , MSD High Top
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Old 09-20-2017, 02:37 PM   #2
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roof rack build
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2017-02-04 10.39.15.jpg   2017-02-04 14.12.50.jpg   2017-02-11 12.28.40.jpg   2017-02-12 16.20.53.jpg   2017-02-12 16.21.10.jpg  

2017-02-12 15.55.02.jpg  
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Home Built Camper Van - 2003 EB 15 Passenger, 7.3 PSD, Ujoint 6" Lift, 35x12.50x17E BFG AT2 , MSD High Top
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Old 09-20-2017, 02:40 PM   #3
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removal of old home made roof rack and test fit of the top. monstaliner lower part of van, ladder steps, and roof rack. Total redneck hoist setup in our oak tree
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2017-02-22 16.07.37.jpg   2017-02-22 18.01.27.jpg   2017-02-27 13.04.24-1.jpg   2017-02-27 16.02.41.jpg   2017-03-01 18.00.57.jpg  

2017-02-27 17.53.16.jpg  
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Old 09-20-2017, 02:41 PM   #4
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adding solar and cargo box to roof rack, sttached roof rack to the top and rolled it over to the oak tree. Hoisted up in the oak tree as one unit and set on top of the van.
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2017-03-02 17.28.28-1.jpg   2017-03-04 13.03.59.jpg   2017-03-04 17.14.15.jpg   2017-03-04 17.14.31.jpg   2017-03-04 18.23.27.jpg  

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Old 09-20-2017, 02:47 PM   #5
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I did not cut the roof off until the top was in place because I was super worried that if the top fell from the tree some how I would have no top and a convertible van. Once the top was set I cut out an access hole and made about 3-4 rough cuts before the final cut was made inside a few weeks later.

Because the MDS top uses adhesive to secure it, and I was going to have wome weight up there, I decided to tie the roof into what was left of the van roof. Using some aluminum flat bar and grade 8 hardware I made brackets that attached to a 2" flat bar back plate that bolted through to the roof rack mounts. I put a bracket on each corner of the top. It also gave me something to attach the wood interior to which you'll see later in the build
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2017-03-05 09.12.59.jpg   2017-03-05 09.32.31.jpg   2017-03-06 19.15.50.jpg   2017-03-06 20.44.45.jpg   2017-03-09 12.32.34.jpg  

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Old 09-20-2017, 02:48 PM   #6
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more pics of the inside of the top. I left the back section of the roof in place since I was going to have a bunk/storage area there.
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2017-03-22 11.25.40.jpg   2017-03-22 11.26.42.jpg  
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Old 09-20-2017, 02:53 PM   #7
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some of these pictures are a little out of order. I was jumping back and forth between sections of the van over the course of 3 months. Here is the over head console. I had custom switches covers made by OTRATTW.com. I also found some 4 runner sun visors that have two parts and slide on the bar so you can position them all sorts of ways.
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2017-03-24 20.45.45.jpg   2017-03-26 16.26.52.jpg   2017-04-01 11.31.52.jpg   2017-04-13 19.01.18.jpg   2017-04-13 21.14.04.jpg  

2017-04-13 22.02.59.jpg  
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Old 09-20-2017, 02:57 PM   #8
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here is the part of the finished product. Lots of cardboard templates used. I also used the edges of the old headliner board to get that transition to look right. First stab at upholstery work, 3/16th foam with micro suede on top. My icom 2 meter and midland GMRS radios are mounted in the console
Attached Thumbnails
2017-04-21 18.41.10.jpg   2017-04-21 19.47.04.jpg   2017-05-11 13.39.11.jpg   2017-05-11 14.22.04.jpg   2017-05-11 18.04.22.jpg  

2017-05-12 09.24.26.jpg  
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Old 09-20-2017, 02:59 PM   #9
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mostly finished overhead console. Not seen in these pictures are flexible gooseneck lights I bought from kartco.com
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2017-05-12 09.42.27.jpg   2017-05-12 09.54.17.jpg   2017-05-12 10.14.05.jpg   2017-05-12 10.43.27.jpg   2017-05-12 11.18.58.jpg  

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Old 09-20-2017, 03:02 PM   #10
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onto the rest of the interior. I used 1"2 baltic birch for the floor. I used the old carpet as a template and used the birch floor as a template for the g-floor coin floor from home dept. I plugged the unused holes with m12 caps and silkaflexed them.
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2017-04-14 08.40.33.jpg   2017-04-14 08.58.35.jpg   2017-04-14 10.44.02.jpg   2017-05-02 18.06.27.jpg   2017-05-05 17.45.40.jpg  

2017-05-05 17.13.57.jpg  
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