Restoring/Updating older Xplorer RV (1989 Ford E-350 van)

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<strong>UPDATE&nbsp;</strong><br><strong>AUGUST 17, 2013</strong><br><br><br><em>Electrical</em><br>House battery "case" built and wired in. The system is fully isolated and protected with circuit breakers. Only thing left to do is wire three separate circuits for the console, fridge (if I ever buy a 12v fridge again) and fog lights.&nbsp;<br><br>The vent fan was not working at all. Dad replaced a faulty switch and added some new features: a three-way switch to reverse the fan's air flow, and a kill switch in the bedroom so I can turn it on/off without having to get out of bed.&nbsp;<br><br><br><em>Interior</em><br>Laminate Flooring is down! Carpet is down!&nbsp;<img src="/images/boards/smilies/smile.gif" class="emoticon bbc_img">&nbsp;It was not unexpected, but the laminate flooring isn't staying down flat. I think it's just something to live with. I've decided not to add trim until I've had a few months to decide how much I like the laminate.&nbsp;<br><br>I had enough laminate left over I decided to incorporate it into my desk. I even added a strip to the leg. I'm particularly proud of this accomplishment.<br><br>The carpet was much easier to work with. I made a pattern out of several pieces of cardboard. That took the most time. I found a reminate that worked out great. I spray-painted the metal trim bars too. I think it looks great.&nbsp;<br><br>The 3-way fridge was replaced by a 110 dorm fridge and a custom-built shelf. The shelf is recycled material from a coffee table I made myself when I had a house. I love recycling!&nbsp;<img src="/images/boards/smilies/cool.gif" class="emoticon bbc_img">&nbsp;The space under the furnace had some water damaged wood that I replaced. And I also painted the furnace cover white.&nbsp;<br><br>I also decided to paint the toilet. One of the hinges was broken and I glued it back together with JB Weld. The new paint job covers up the Weld pretty well and the lighter color (yellow to white) makes it look newer/more expensive.&nbsp;<br><br><br><em>Exterior</em><br>I treated rust on the propane tank and painted it, black. I was then told that DOT regulations require the tank be silver/gray, so I painted it again.&nbsp;<img src="/images/boards/smilies/biggrin.gif" class="emoticon bbc_img">&nbsp;I also applied Bondo and painted the rust hole under the fridge. It's not the neatest looking job but you'll have squat down to really examine my work.<br><br>I also installed two new front shocks. I went with KYB's Gas-a-Just since I used to work for that company and I wanted something "heavy duty." I haven't driven it enough to know if it will make much of a difference in the steering. I word of caution to others: don't do this job alone.&nbsp;<img src="/images/boards/smilies/nono.gif" class="emoticon bbc_img">&nbsp;I used a hydraulic jack to compress the shock so the mounting hole would line up with the mount. I then reached up with my hand to fine-tune the alignment and...the shock slipped off the jack and pinned my finger between it and the mount.&nbsp;<img src="/images/boards/smilies/eek.gif" class="emoticon bbc_img">&nbsp;Luckily, it just caught the skin, my finger is safe. However, I was pinned, trapped under the car with no help, and my phone out of reach. I yelled for help, but no one heard me. I was in extreme pain and panicking. My cooler head prevailed and I was able to move the jack back into place and jack the shock off my finger. It could have been much worse. So, learn from my mistake!&nbsp;<br><br><br><em>Summary</em><br>It's been over two weeks of long days. I'm so ready for this to be over. I'm almost finished. I was thinking of replacing the ceiling in the bedroom, but I'm so tired now I thinking of leaving it. It's not that bad. <br><br>I drove it home yesterday. It was the longest I drove it since I bought it. It seemed to run fine, but when I pulled into the driveway about 5 miles later, steam was coming out of the hood. The top radiator hose was spitting hot fluid out. I'm not sure, but it might have been leaking from other spots as well. Kind of fustrating, but maybe all I need is a newer, tighter hose clamp.&nbsp;<br><br>Today I'm planning on getting new tires installed. Still on the to do list: fill and test water system; Cap unused fridge propane and test range and furnace; install and test toilet. Soon, baby, soon.&nbsp;<br><br><br>Pictures:<br>Propane tank, before I painted it silver again:<a href="/file?id=1620896" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620896" class="bbc_img" alt="P1010731.jpg"></a>&nbsp;<br><br>The front carpet installed:<a href="/file?id=1620897" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620897" class="bbc_img" alt="P1010732.jpg"></a>&nbsp;<a href="/file?id=1620898" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620898" class="bbc_img" alt="P1010735.jpg"></a>&nbsp;<a href="/file?id=1620899" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620899" class="bbc_img" alt="P1010737.jpg"></a>&nbsp;<br><br>Laminate flooring and desk:<a href="/file?id=1620900" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620900" class="bbc_img" alt="P1010750.jpg"></a>&nbsp;<a href="/file?id=1620901" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620901" class="bbc_img" alt="P1010751.jpg"></a>&nbsp;<a href="/file?id=1620902" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620902" class="bbc_img" alt="P1010752.jpg"></a>&nbsp;<a href="/file?id=1620903" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620903" class="bbc_img" alt="P1010754.jpg"></a>&nbsp;<a href="/file?id=1620904" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620904" class="bbc_img" alt="P1010755.jpg"></a>&nbsp;<a href="/file?id=1620905" rel="lightbox" target="_blank"><img src="http://files.websitetoolbox.com/82529/thumb/1620905" class="bbc_img" alt="P1010756.jpg"></a>&nbsp;<br><br><br>
 
<em><strong><span style="color: #888888;">Really nice work.Good to have family in the electrical trade. I reckon that was a great help to you. <br>Satifying when that engine kicks back into life.<br>Geoff</span></strong></em>
 
UPDATE
AUGUST 22, 2013


ENGINE
I took the beast out for tires this Saturday and it died in the waiting line. After a tow by my very generous parents (Saturday was their 35th wedding anniversary) I got it running again. I was sure it was just overheated. I added some coolent and let it rest for a while.

It ran fine for about ten minutes, then died as I was pulling into the grocery store. I can't think of another place with more foot and vehicle traffic. :'( This time I got it towed all the way home.

On Monday I replaced the old house clamps on the radiator hoses, and added some silicon sealant as well. That seems to have stopped the leaks.

Tuesday was a long day. It was still dying randomly. After a lot of internet research I decided to replace some ignition components. My new cherry-red MSD ignition coil looks nice against the old engine. I also replaced the Ignition Control Module. Now it starts right up and runs! :)


EXTERIOR
Yesterday I made holes in the side of the van. :) I installed an exterior 110 and 12 volt outlet and a cable TV jack. I don't know if I'll use these often, but it's nice to have the option and it will hopefully increase its resale value.


SUMMARY
Yesterday marked three weeks I've been working on this project. I think I'm close enough to being done that I'm going to take it out this weekend to a nearby park.
 
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