What's next for my old Sportsmobile?

[geoffff]

I bought this Sportsmobile 4x4 new in 2004, and after 20 years of hard use almost everything about my van is wearing out, except the V10 engine itself. The old van is now rusted and cracked and leaking, and I just can't trust it going too far from civilization anymore (the whole point, in my book).



I'm at a bit of a loss as to how to proceed.

I have looked hard at other 4x4 camping vehicles ("Classic" Field Van cutaway with fiberglass rear, slide-in campers, Tiger, Earthcruiser, Transits/Sprinters, trailers), but I keep coming back to this same Sportsmobile E-Series RB-50 penthouse-top van design, with its beefy drivetrain, a real 4x4 low-range system, integrated cab and living area, and panoramic views when camping.



My only real complaint (other than generally mediocre interior build quality) is the lack of vertical travel in the front end of Sportsmobile's 4x4 conversion. Only 1" vertical travel until I hit the bump stops. This is a huge pain, with a punishingly rough ride off-pavement, and has likely led to vehicle damage as I learned over the years to properly drive on the bumpy stuff.

I see two paths moving forward:

• I spend a bunch of money getting my van completely rebuilt, like body-off-frame restoration
• I spend a comparable amount of money buying someone's 10-year-old RB50 super-clean campsite-queen 2WD Sportsmobile, and have someone like UJoint convert it to 4x4.

Every "solution" seems to invite more questions...

For example, U-Joint says they cut the stock ~35 gallon tank down to fit the transfer-case. I really don't want a smaller gas tank! One of things I love about my current van is the 46-gallon Transfer Flow tank. I use every one of the range miles it gives me. (Which makes me wonder – is the 46-gallon Transfer Flow mandatory on all E-Series Sportsmobile 4x4 conversions, to make room for the T-Case?)

On the other hand, maybe the Sportsmobile 4x4 system can be lifted another couple inches (from 4" to 6") giving me 3" of upward suspension travel on the front end? Has anyone increased the lift on their Sportsmobile 4x4?

Anyway, this is what I have been thinking about all the time recently.

Please feel free to chime in with your perspective!

-- Geoff

 

[Twoxentrix]

I feel like anything I'd say would disrespect the emotional attachment you still have for your Van, along with the sentimental value inspired by all the cherished memories it's so honorably provided for all these years.
I too have looked (and drove several) at the options you've mentioned...just not the same as the Van I've come to appreciate (and guess 'tolerate' as well).
If I were currently faced with the same, I'd seek a replacement Van and tweak it to suit my needs (have a slight lift installed)...much less of a financial burden than investing in a new 4x4 system and/or pop-top.

 

[geoffff]

Yeah, I am not really holding onto the rebuild-my-van plan, unless someone convinces me it's a good idea. So much is broken/worn out.

I think a "new" (about 10-year old, actually, as they don't make these vans anymore) used E-Series Sportsmobile 2WD (converted to 4x4 by UJoint or Quadvan), or a Sportsmobile 4x4 (modified to have more of a lift -- can this be done?) is my path forward.

2WD used Sportsmobiles out there seem to go for half the $ money as 4x4 ones.

The trick is to find something that has the same layout and toys that I've grown used to (like the large gas tank).

 

[loper]

Man, 20 years and some of those pictures, I'd say you got use out of that ol' girl!

We've only had our van about 4 years, but it's a 2000 so it's still old. I think about when things start wearing out, and at what point do you give it up for a lost cause. Right now I have a long way to go.

On mine the axles were rebuilt less than 10K miles back, and the tranny was rebuilt at the same time in the 4x4 conversion. The body is pretty solid, the interior is doing good (we did the build ourselves, so it's new-ish) my only real concern is the engine. I have 178K on the V10, and I know there's a limit. As it stands, I plan on (and have the money set aside for) dropping in a new Jasper engine when the time comes.

If I had to start from scratch, I might do a box truck. We've also looked at ambulances, but something about the clean canvas of a box truck just gets me thinking...

As for front suspension, Mine is a 2005-up coil/radius arm set up, with about 3" to the bump stops. once I got it stiff enough for the weight, I'd say it rides pretty good off road.

I don't know man, but I hope whatever you do next gives you another 20 years of good service!

 

[86Scotty]

Find a newer van and keep your tank. Swap out tank on new van with yours and carry on.

E-series deals are dropping from the sky lately. I would keep an eye open for a good candidate.

If you don't find one with everything you are looking for then assemble one. A CCV top is a great upgrade from SMB. Lots of other builders/converters can upgrade the cabinets.

I've always enjoyed your adventures and pics Geoff! I hope you stay with the E-series platform but more than that I hope you find what you're looking for.

:b5:

 

[geoffff]

If I had to start from scratch, I might do a box truck. We've also looked at ambulances, but something about the clean canvas of a box truck just gets me thinking...

I've also thought about a box truck. E-Series cutaway, like a 10-ft rental "truck" van. (But not an ambulance -- I want a narrow vehicle (no duallies), gasoline engine, and standing height.

But I don't have time in my life right now (or ever) to personally build something custom like this. Also, I have concerns that a box truck (van) might not handle frame-flex offroad.

In any case, here are some examples I drool over, and my own box truck sketchups:

 

[geoffff]

Mostly I get overwhelmed thinking about managing all the moving pieces of a custom build, buying a used van, getting it to the 4x4 converter (U-Joint, perhaps), finding someone to swap my tank, getting the van over to CCV, perhaps (as 86Scotty suggests). I can't really be flying/driving all around the country.

Sportsmobile made it so easy in that they did everything right there in Fresno -- the 4x4 conversion, RV conversion, pop-top.


I would love to find a General Contractor, but for building campervans!

 

[86Scotty]

Lol, I understand that! I too love the box van idea but I just did a couple hundred miles offroad this past weekend in the woodsy eastern US and it once again reminded me why there's nothing better than an E-series......that you're willing to scratch.

 

[1der]

Whatever you do KEEP THE TRANSFERFLOW 46 Gas tank!!! Use it another van or sell it

 

[geoffff]

Whatever you do KEEP THE TRANSFERFLOW 46 Gas tank!!! Use it another van or sell it

Probably wise! Though it means I can't use my old van while my new one is being built, and selling or moving the remaining van might be tricky without a tank.

I think the stock Ford tank won't fit with the transfer case in there. (At least that's the case for a U-Joint 4x4.)

Anyone know if Transfer Flow still makes 46-gallon tanks for the E-Series?

 

[1der]

Anyone know if Transfer Flow still makes 46-gallon tanks for the E-Series?

They only ever made them to order for SMB and Quadvan. Never available retail. Now I do not think they are making them at all.

 

[geoffff]

They only ever made them to order for SMB and Quadvan Never available retail. Now I do not think they are making them at all.

Wow! That explains things. OK I'll never give mine up

Here is a Transfer Flow "prototype" I saw behind the Quadvan building!

 

[1der]

Wow, pretty amazing pics of the prototype.

That reminds me somewhere in my "stuff" I have (or at least used to have) an actual drawing set of the TF 46 Tank. No clue as to how I got it.

 

[geoffff]

 

[boywonder]

This:

Find a newer van and keep your tank. Swap out tank on new van with yours and carry on.

...and this......

A CCV top is a great upgrade from SMB.

 

[loper]

Off topic, but there is also Hanco fabrication. Makes aluminum 45 gallon diesel and 40 gallon gas tanks that fit 4x4 E series. So increased fuel capacity is still available.

 

[vanagonman]

I would vote to rebuild the preexisting van especially if you like the current interior layout, any other van you purchase is going to have surprises given the age now.

Based on the pictures you have shown I wouldn't call that van spent, now if there is actual frame and body seam rust than that is a different story.

I would go down the path of rebuilding the 4wd system with a kit that has more travel.

 

[1der]

Off topic, but there is also Hanco fabrication. Makes aluminum 45 gallon diesel and 40 gallon gas tanks that fit 4x4 E series. So increased fuel capacity is still available.

Contact info.. 970-852-0888
Actually spoke to them a few months ago.

For diesel Aerotanks in SoCal is the deal.

Hanco is pricey but work looks solid. UJOR Colorado has installed a few Hanco' tanks on their conversions.

 

[geoffff]

I would vote to rebuild the preexisting van especially if you like the current interior layout, any other van you purchase is going to have surprises given the age now.

Based on the pictures you have shown I wouldn't call that van spent, now if there is actual frame and body seam rust than that is a different story.

I would go down the path of rebuilding the 4wd system with a kit that has more travel.

Well, the van isn't too messed up, still, for messing around locally, doing some easy camping, but the reason I have this van and not some AWD Sprinter is that I like to take it really remote (deep Baja etc.) all by myself where I'd have to hike out a day or two if something went wrong. (Hasn't happened yet, knock on wood.) So I really want something reliable.

Here is what I know is wrong with the van right now:

• Lots of cracks (like 10+) in the body near where it attaches to the frame (body mounts). I've welded up many of these cracks, but I keep finding more. These were probably caused by me hitting the bump stops hard many times over the years. (I learned a lot driving this van.)
• Long rusty cracks at the corners of the side windows that run diagonally all the way to the roof (from years of awning shake, since removed)
• Rusty cracks at the corners of the driver and passenger door openings
• The underbody is surface-rusted from beach camping, but not too bad.
• Problems with frame flex when the axles are diagonally oppositely twisted. Engine belts rub and smoke, and the air conditioner condenser keeps popping loose. Probably engine mount issue (again!), but I wonder if I should see about adding some custom extra frame crossmembers to stiffen the frame.
• Hood hinges broken
• The 4R100 transmission revs up unexpectedly at times (rare).
• Transfer case is slowly seeping fluid
• Engine stumbles and dies at times when cold.
• Power steering is almost nonexistent when van is first started in the morning.
• Penthouse screens are starting to get some holes (can the screens be fixed without removing the penthouse fabric entirely?)
• Penthouse canvas fabric is wearing (from bouncing and rubbing) in many places, but I keep adding patches.
• Penthouse clearcoat is cracked
• All kinds of interior squeaks and rattles in places I can't easily get to (I drive with earplugs.)
• A bunch of cosmetic things in the interior, like the MDF expanding from floor moisture, but that stuff is not important

When I see all this, I also worry about all the stuff I can't see. All the cracks that I haven't found yet, but are down there silently growing.

So far over the years I've noticed cracks in (or found out too late when they were obviously broken) and replaced my: tie-rod, anti sway bar disconnect, front leaf spring, rear spring shackle.

Anyway, all the above doesn't sound impossible to fix. But if I am going to trust the van way out there on my adventures, I would want someone trustworthy to go over the whole van and find and fix all the problems. Like a body-off-frame rebuild and repaint. This sounds expensive to me. And I have trouble finding 4x4-savvy mechanics here in Seattle.


Might it just be cheaper for me to buy someone else's van that has only seen campground use over its 10- to 15-year life?

Used 10-20 year old Sportsmobiles seem to bring asking prices of $75K upward to $150K for a 4x4 ... and much less, like maybe $50K for a 2WD (though I haven't looked at as many of those).


To put it in perspective, I paid $75K for my van new 20 years ago ($150K in today's dollars).

 

[geoffff]

Contact info.. 970-852-0888
Actually spoke to them a few months ago.

For diesel Aerotanks in SoCal is the deal.

Hanco is pricey but work looks solid. UJOR Colorado has installed a few Hanco' tanks on their conversions.

Thank you, that's great info!!