The mod list for this van, at least for now, is pretty simple. I've been concentrating on wiring and suspension these past weeks. I pulled the dash apart to add a Pioneer Apple Carplay compatible stereo. While apart I added some USB outlets in the dash, wired for driving lights and the trailer controller. And I installed the trip camera I pulled out of the Ford before I sold it.
While running all the wires under the carpet front to rear I added some extras for future use, plus a feed over behind the drivers seat for the Engel fridge. Plus I added a 110V feed outlet to the back bumper so I can run a trickle charger to the house battery, and a 110V feed to the fridge. With the wires all run I still need to build a small cabinet to place the chest style fridge on, add my 100W Solar panel on the roof, and figure out where I'm going to store the deep cycle battery.
On the exterior I replaced the headlights and taillights. The headlights are exact copies, just not all yellowed and dingy. They don't make stock style taillights for these vans. The aftermarket style lights are not my favorite, but they are cheap. I'll run them until I find some decent stock ones.
Added LED floods to the back bumper, wired into the reverse light circuit. I had these on my E350 and loved the illumination while backing up. Added a backup camera. The second one I've purchased with a Sony lens. Those Sony lens cameras have excellent clarity.
Purchased a 2" front, 1-1/2" rear lift kit. The actual coil spring puck is about 1" in height, for a 2" lift. I fought getting them installed. No matter how far I compressed the spring, I needed one more hand to get the spring back into its seat. My nephew dropped by and I pressed him into service. Went pretty quickly after that. With the 1" puck in place the shocks just reached their mounting spot. They bolt on under the a-arm normally. If I had bolted my new Bilstein shocks on like that, they would have been destroyed pretty quick as there was absolutely no down travel with the shock in place. At first I was thinking I could get a shock extender for the top of the shock to lengthen it, but after some studying, I realized I could bolt the shock in on top of the a-arm and get the 1" of travel back I lost with the puck.
The rear was lifted using a 1-1/2" lifting block. The kit I bought came with round u-bolts like the Ford would use. But the Express uses square u-bolts. This kit was marketed expressly for the Express, so I don't know what they were thinking. I didn't realize they were wrong until I moved to the back after installing the front spacers.
After a quick search, I found an online vendor, Stengel Brothers, that sells the u-bolts in the length of your choice. Meanwhile the van had to set in a butt down position for a week.
With the little bigger than stock alloys, and the modest lift, these are subtle changes that most won't even realize I've done. But I know, and I like the way it drives, handles and looks. After driving the extended Ford with the hightop, this van feels very nimble.
I'm trying to not do so much that I greatly impact fuel economy. On the Ford, every mod I did dropped mileage 1 mpg here and 2 mpg there. I got 17 MPG in this stock and hope to stay close to that when not towing. Have a 200 mile round trip planned this weekend so we'll see where we're at mileage wise.