Forrest - 2002 E350 7.3L Build

BenJJ-SMB

Senior Member
Joined
May 17, 2017
Posts
430
Location
San Clemente, CA
Alright I think its time I start an official build thread. Some background first:

About 5 months ago my wife and I decided that we wanted to upgrade our junkyard restored SMB pop-top to a high roof CCV pop-top. First van build thread here:

https://www.sportsmobileforum.com/forums/f24/2003-7-3-cargo-van-build-19704.html

We loved that van and were ready to commit to it long term. There were however a few things that were undesirable. No power options, no cruise control, slider instead of barn doors, etc. Pretty standard cargo van vs passenger van issues. So we agreed to move forward getting a quote from CCV but if a passenger van with all of those options popped up we would buy it and start over with the new van. I was not willing to swap to a different engine so that made the search challenging.

As luck would have it, just as we were finalizing our quote with CCV on Vanna White, I found the one. Enter Forrest, a 2002 7.3L passenger van with the Traveler's Package and only 118k miles. Only box it didn't check was it had a slider and not barn doors but I was willing to compromise. The leather chairs, power windows and doors, cruise control, and double captain setup was too good to pass up. It was also just immaculate inside and out for its age.

I just picked him up from CCV yesterday! I had them install a new floor, high roof pop top, two 100ah batteries and raptor liner both the top and the bottom rocker panels. I think it turned out incredible!

As far as the name goes my older brother came up with it due to the color and my favorite movie being Forrest Gump.
 

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So CCV was the first phase of the build. Phase 2 is Weldtec where it will get their 6" Baja Grocery Getter lift, front and rear bumpers, on board air, re-gear to 4.10 with rear air locker, and some 17" method wheels with 33" BFG KO2s! That starts tomorrow!

Once it gets back from Weldtec I will start working on installing my wheel well cabinets. Details for those are in a separate thread:

https://www.sportsmobileforum.com/forums/f19/diy-wheel-well-cabinets-26866.html

Plan is to make a removable bed platform to go across for the kids to sleep and then have a slide out kitchen underneath with fridge, stove, and sink on it. Fridge is a Dometic CFX3 100... its big.
 

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Following along for sure! You had me with the cabinets. Excited to see it all come together!

I wish I would have found the van you did. Looks like a great 4 person setup!
 
Nice project and a great engine, but be ready to swap out the up-pipes on between the headers and the turbo, if that hasn't been done already. Our 2002 7.3L needed them at 140k miles. (Look for black soot and/or burn marks on the aluminum-faced insulation on the inside of the "dog house".) It's not a hard job to swap these exhaust pipes out in a van (harder in an F-250), and ProSource Diesel has the 409SS pipe kit on sale right now, for about $140, I think.

Great-looking van - enjoy!
 
Looks good! Any chance you saved the carpet? Mine is beat and I've been wanting to replace it.

I did not, CCV took it out when they installed the new floor. If you want the front and rear bumpers though you can have those. Weldtec is going to take them off and I don't want them.
 
Congrats. That's a very clean looking rig, inside and out. I see you're using the Dometic CFX3-100 as you fridge. How do you like its performance? I'm considering that model to replace my built-in Norcold 2cu ft unit as supplied by SMB.
 
Congrats. That's a very clean looking rig, inside and out. I see you're using the Dometic CFX3-100 as you fridge. How do you like its performance? I'm considering that model to replace my built-in Norcold 2cu ft unit as supplied by SMB.

I actually haven't used it yet haha. Van went straight from CCV to Weldtec. Once I get it back and do a trip or two I will let you know how it works!
 
Picked Forrest up from Weldtec yesterday... looks absolutely incredible. Ended up going with the bronze Con6 method wheels which I never thought I would do bronze but I love the end result.

I had Jeremy add a front hoop to the bumper which again turned out great! Their dual swing out rear bumper is also just super heavy duty. Honestly there is no comparison to the aluminess rear bumper. Having used both it is night and day different.

He did the full 6" front end suspension package (new bent I-beams, radius arms, coils, fox reservoir shocks) and new leaf springs for the rear end with fox shocks. ARB on-board air compressor with rear air locker, re-geared to 4.10.

Could not be any happier with the final product. Only thing that isn't quite right is the slider extender isn't long enough to clear the tires. He ended up adding 1.5" spacers to the rear which I think caused the issue. Plan is for me to take it home for the weekend to install the fender flares and do some interior work and then bring it back down to him later for a longer slider extender that will clear both the tire and bushwacker flare.
 

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As good as I think it looks now, I have a set of bushwacker fender flares and a new front grill that I painted with black raptor liner to install which will make it look even better. Also have a set of Vantage optic headlights to put on. I'll post more pictures once I have it all on.
 
Looks great! bet you're excited to just get out and do something in it...anything!

Those Vantage Optics headlights will transform you're night time driving experience.
 
Last edited:
Looks great! bet you're excited to just get out and do something in it...anything!

Those Vantage Optics headlights will transform you're night time driving experience.

Oh yeah! End of this month we have a trip planned out in Anza Borrego, then Mojave Preserve early November, and then Big Sur for Thanksgiving. Just need to make sure everything works by then. Going to be a busy weekend.
 

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