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BenJJ 06-09-2017 08:49 AM

2003 7.3 cargo van build
4 Attachment(s)
After months of lurking on Craigslist I finally found the one and pounced this past week to start my first van build. It is a 2003 Ford e350 7.3 power stroke diesel with 91k miles! It was government owned previously, so was very well maintained.

Sorry for the bad pictures, driveway was too narrow to get a good angle and I backed it all the way up to my garage. Also on mobile and some of the pics came up the wrong direction.

Time to let the fun begin!

BenJJ 06-09-2017 09:01 AM

First goal, remove all the shelving. Easy right?

We are headed up to Yosemite this weekend and I basically had a 2.5 hour window to actually work on it after work. Grabbed my tool set and a coors light and started going to town, mostly just to realize within 5 minutes that there is no way I am going to be able finish and it is going to be way harder than I thought.

Bemerritt stopped by and helped me get one of the shelves out, and then I got about 90% of the way on the front divider. Unfortunately I couldn't get at the last couple bolts because the huge weather guard drawer was in the way. But I can't get the weather guard drawer out because the front divider is in the way....

So I left it there and had to pack for the Yosemite trip.
The van will have to wait sadly.

bemerritt 06-09-2017 09:45 AM

Taking out the annoying shelves in a cargo is a right of passage!

shenrie 06-09-2017 10:36 AM

congrats man!

we had to do the same thing only the dealer we were working with were so awesome that they were willing to remove some of that stuff for us so we could at least fit an air mattress in the back for the drive home. didn't have near as much stuff in the back as yours though...

try not to think about the van too much over the weekend ;)

BenJJ 06-09-2017 10:43 AM


Originally Posted by shenrie (Post 205011)
congrats man!

try not to think about the van too much over the weekend ;)

HAH. If only it were that easy. Really wish I had more time to work on it so I could have driven it out there. Instead I am in my in-laws Toyota Sienna which I secretly am planning to take the captain chairs from.

shenrie 06-09-2017 11:05 AM

^^^ lolol, just leave a few folding chairs in there to replace them??

BenJJ 06-14-2017 11:38 AM

4 Attachment(s)
Finally got some time to work on the van and removed all the shelves! Only had to cut one of the mounting brackets for the weather guard drawer because one of the bolts was physically impossible to access from underneath the car. Also some of the upper brackets holding the side shelves in will be a problem. Pictures attached. If anyone has any good ideas on how to get these off short of cutting/grinding the bolts down I am all ears.

Goal for this weekend will be to remove the current floor and patch all the holes from where the shelves were mounted. Any suggestions on the best way to do that would be appreciated!

Side note: Huge win for the neighbors... I found the reverse speaker and cut the wire so they don't have to listen the beeping every time I back in the driveway.

Also threw in one of my favorite pics from the yosemite trip last weekend. Waterfalls everywhere!

rallypanam 06-14-2017 12:01 PM

Welding is best for filling holes.. but also the most complicated.

bemerritt 06-14-2017 12:09 PM

Lucky for him he has less than 20 holes and I have a mig welder...

grind, disconnect battery from frame, grind, reconnect battery, paint

Paging Flux to tell us how many holes he had!

I didn't do it this way and in hindsight I wish i did.

bemerritt 06-14-2017 12:10 PM

Oh, and have a backing plate, probably copper

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