E-250 stealth conversion

[daminc]

I suppose I should start my build. Just ordered new hinge pins, and paint for my van. I see a little rust on the doors and a bunch underneath, so before I can put a hightop on it, I need to get rid of all the rust. a hightop van will never fit into my shop, so this will be the first step, along with cleaning it out and getting rid of a lot of shelving that I don't really use for my business anymore.<br><br>I found some power front door panels, along with all the power goodies in the doors, Panels are resprayed already as of Saturday.<br><br>Also thinking I may be able to use my 6 way power seat setup out of my 87 cougar, I happen to have a few extras kicking around from when I restored it. Driving is always more enjoyable when you can get the seat in the perfect spot.... A little cutting, a little welding.... should work OK<br><br>&nbsp;I'll take some before pics tomorrow, living in Buffalo NY is brutal on cars with all the salt we use... fortunately, I didn't drive it very much in the winters.<br><br>here's a starter&nbsp;<br><img rel="lightbox" src="http://i233.photobucket.com/albums/...1-622b-40a4-aa4d-12a672af6f3d_zpsd7feb933.jpg" class="bbc_img"><br><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2223_zpse59bbde2.jpg" class="bbc_img"><br><br>So thats my start... I think this my be a long build<br><br>Jerry<br><br>

 

[coultergeist]

Looks like a good start.&nbsp; It may take a while, but you will appreciate it that much more in the end when it's done.&nbsp; Looks like it will be a great conversion when it's done.<br><br>Patrick

 

[daminc]

Time to downsize and move tools into my Ford Ranger..<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/IMG_2228_zpseec7c622.jpg" class="bbc_img"><br><br><br><br>After doing some investigating, It's actually not so bad for the amount of salt they toss on our roads. I expected a a lot worse for a 10 year old van thats only been washed 4 or 5 times in its entire life<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/IMG_2231_zpsfb8c3e4e.jpg" class="bbc_img"><br><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/IMG_2236_zpsb046f506.jpg" class="bbc_img"><br><br>Worst spot on the entire van... unfortunately, I've repaired much worse on my vehicles in the past<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/IMG_2234_zpse2fce05f.jpg" class="bbc_img"><br><br>Hopefully the weather will get better soon, They talk about sleet and snow later this week and highs of 30. Looks like I'll be cleaning out the inside this week

 

[wagoneer]

Do not overbuild keep it simple leave some room.

 

[daminc]

Decided to empty the van. Also got my hitch receiver today. I'm going to make underfloor storage in the rear, and noticed that the shelving I removed was thick enough to make a storage box with., and its also the correct shape and depth. A bunch of cutting and welding, and I have a free storage space for my project..<br><br>i put some tape at 24".... I'll have to shorten it by about 10", and weld the holes shut, but its a jump start to building it. I even like that it's already angled .<br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/IMG_2272_zpsefba590f.jpg" class="bbc_img"><br><br>As long as I'm coating the underside... its the best time to check the inside of the floor for rust, install the receiver, and install the storage box. so far it looks pretty new inside. and a lot bigger then what I'm used to seeing.<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/IMG_2270_zps0865758c.jpg" class="bbc_img">

 

[daminc]

things are slow going, but still happening<br>had to wait for my T-lok to arrive, and be installed before I start on the repairs and underfloor storage area<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2320_zpsb5ec8b51.jpg" class="bbc_img"><br><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2325_zpse7b57736.jpg" class="bbc_img"><br><br><br>While it was up on the lift, we relocated the canister and removed the spare tire carrier. Now I have plenty of room for storage<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2327_zps1d64b6ab.jpg" class="bbc_img"><br><br>and I got this for rear frame support, and towing.<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2276_zps11681183.jpg" class="bbc_img"><br><br>now I can start the body work and repainting while I'm trying to locate a high top... Hope to find one at a decent price before winter

 

[vokus]

Nice! <br><br>Please post as many pictures as possible, as it very helpful to this community! <br><br>Thank you for sharing with us!

 

[daminc]

paint touch up is complete<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2342_zps90d0dcfa.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2343_zps5dfaf190.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2344_zps1c2a5bfd.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2345_zps98698a41.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2346_zps7fb9a9ea.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2347_zps33377eee.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2349_zps7ce4a6af.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2351_zpsef661f53.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2352_zpsbaca3ec4.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2353_zps8761dde1.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2354_zps3180f38d.jpg" class="bbc_img"><br><br>finishing putting everything back on the van this week, Got new hubcaps, and the hitch receiver is bolted on.<br>I'll be ordering a 24" hightop from Fiberine shortly, the shipping is a little pricy but I hear they are very well made compared to others..&nbsp;<br>WHile I'm waiting, I'll build my under floor storage, install the running boards I got last week, and plan for making side compartment storage on the drivers side for storing my hoses, and waste outlet for the gray and black tank...I have an idea using 14" high underframe toolboxes, and setting them on my running boards, and cutting them into the side of the van....thinking I can get 2 24" long boxes in there with a little modification of them.<br><br>I also coated the entire underside of the van with zero-rust, to stop it from getting any worse then it is..... pics for that are coming soon<br><br>after the hightop gets put on, I can finally start my build

 

[daminc]

oh, I also have to buff out the rest of the van to clean it up....&nbsp;<img src="/images/boards/smilies/smile.gif" class="emoticon bbc_img">

 

[stude53]

<span style="color: rgb(0, 128, 0);"><strong><span style="font-family: arial,helvetica,sans-serif; font-size: medium;">Looks like you are doing a great job, daminc!&nbsp; <img class="emoticon bbc_img" src="/images/boards/smilies/thumb.gif"><img class="emoticon bbc_img" src="/images/boards/smilies/thumb.gif"><img class="emoticon bbc_img" src="/images/boards/smilies/thumb.gif"></span></strong></span><br><br><span style="color: rgb(0, 128, 0);"><strong><span style="font-family: arial,helvetica,sans-serif; font-size: medium;">Bob</span></strong></span><br><br><span style="color: rgb(0, 128, 0);"><strong><span style="font-family: arial,helvetica,sans-serif; font-size: medium;">P.S. - keep the pictures coming ... we love pictures!</span></strong></span>

 

[daminc]

pics of the underside<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2359_zps365a3adb.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2361_zps96d98fd6.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2363_zpsd719d4ce.jpg" class="bbc_img"><br><br>waiting for the painted bumper to go on<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2364_zps3606a85b.jpg" class="bbc_img"><br><br>all buffed out<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2365_zps8cac8ac8.jpg" class="bbc_img"><br><br>I ordered an aftermarket cruise control unit, should be here on friday...<br><br>

 

[daminc]

things are still going slow... High top will be delivered next Thursday, and I'm thinking about some windows and a sofa bed in the back.. I also plan on building my under floor storage this weekend.<br><br>here's a better pic of the van with a window in tape just to get an idea<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/DSC_8637_zpsb9a47e2d.jpg" class="bbc_img"><br><br>More pics coming as they happen<br>I also notice that this van sits really high for an E-250

 

[ilovemyvan]

Hi Daminic,<br><br>I am so impress with your work. My van wants to move&nbsp;in your driveway and be threated to all this TLC too. You seem to be a master of many trades. The work might be going slow but the results are great.<br><br>I think you probably would&nbsp;enjoy an extra&nbsp;window or two, specially after a few rainy days stuck in the van. We had to change ours. We couldn't find the exact same shape at the junkyards and had to buy it new. They are a bit pricey but you&nbsp; don't have any restriction so you could go to the junkyard and&nbsp;find a good deal.<br><br>I'm looking forward to see the rest of your conversion.<br><br>Cheers,<br><br>Nicole

 

[daminc]

Thanks, I like to fiddle around with things... I may have to rethink the windows until the sofa is in, and the cabinets are planned out. It looks right now that the windows will have to be way smaller then whats marked out on the side of my van....<br><br>so as I have found out like many others here....my spare tire doesn't fit the door bracket, so I had to modify it to work with my tire size<br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2422_zps13e90ded.jpg" class="bbc_img"><br><br>so I made a little alteration and added a couple more bolts<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2423_zpsfaed9675.jpg" class="bbc_img"><br><br>I also had to reposition the tire so the door open all the way, and also has room so the other door closes..&nbsp;<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2424_zps214528c5.jpg" class="bbc_img"><br><br>as I always say..3 bolts are better then 2.. lol<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2425_zpsd3e0ae21.jpg" class="bbc_img"><br><br>so now moving on to todays main attraction....<br>Yep, I cut it out<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2427_zps89617aa9.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2428_zps713fd84a.jpg" class="bbc_img"><br><br>I love to recycle things.... the old shelving from inside the van<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2429_zps7261bca8.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2430_zpse1383e39.jpg" class="bbc_img"><br><br>So I cut it down and built a box using the cut out from the van floor<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2431_zpscc2dcd30.jpg" class="bbc_img"><br><br>zip screwed it together to give it a test run<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2432_zpsa4f289e8.jpg" class="bbc_img"><br><br>dry fit is a success<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2433_zps576b10bd.jpg" class="bbc_img"><br><br>the box is 16 inches deep, and cant even tell its under there<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2434_zps07902397.jpg" class="bbc_img"><br><br>so I removed it and welded it up...<br>and its back in for another test fit<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2436_zps7c5c0d5c.jpg" class="bbc_img"><br><br>you can see I cut the floor to drop the flange on the cross brace under the van<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2437_zpsdab1356b.jpg" class="bbc_img"><br><br>it'll all be seam sealed and bolted into the van.... the box is also seam sealed inside and out after the welding, tomorrow I'll paint it and put it in.<br>the top cover will be made in such a way that I can open the entire thing, or open a smaller door inside of that large door....<br><br>until tomorrow.....<br>6 days until the top arrives.. <img src="/images/boards/smilies/smile.gif" border="0" align="absmiddle">

 

[Wild_E]

I am impressed with your refinishing job !<br>also the creative storage solution to boot

 

[Ziggy Moon]

Wow, very impressive - and very nice. I like the idea of the cut out for the box. <br><br>I've been considering doing something similar to mine, except on the sides - I have a lot of dead space underneath that would be great for storage.

 

[daminc]

I'm also thinking about a storage space on the pass side under the floor, possibly for the batteries, I have to see where the exhaust is in relation to where I want to do this

 

[daminc]

The refinishing isn't perfect, but it isn't to bad either, I'm glad its white, it hides a lot..... in my travels, I may try to find some rust free doors at a J/Y out west, and swap mine out. But for now, I'll get me going. I also hope the hightop matches in color, too, or I'll be spraying that to match before I install it

 

[daminc]

all painted and installed yesterday<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2438_zpsbca9df0f.jpg" class="bbc_img"><br><br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2439_zps70c93632.jpg" class="bbc_img"><br><br>painted the cut metal to stop it from rusting<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2440_zpsad9c9a04.jpg" class="bbc_img"><br><br>put a bead of urethane seam sealer down before box went in, and screwed it down<br><img rel="lightbox" src="http://i233.photobucket.com/albums/ee79/daminc/conversion van build/IMG_2441_zps022ea723.jpg" class="bbc_img"><br><br>&nbsp;have a piece of plywood over it right now until I make a door for it...<br><br>I found that if I stand in the box, I can almost stand without bending my neck. its only 16 inches and I'm 5'10", so my 24 inch top should be great<br><br>4 days until the high top arrives....Its gonna be like Christmas that day....lol

 

[ilovemyvan]

Hi there,<br><br>And I bet you your present will come in a VERY BIG box. I think it takes a brave man to cut a hole on a perfect non-leaking dry floor. The results are amazing! Will you be able to access it without moving too many things once your interior is in place? I'm enjoying following your progress.&nbsp;<br><br>Nicole