Expovans Transit 4x4 Conversions

I realize this thread is more about our 4x4 system but I don't remember if I have a build thread for this rig or not. Been working feverishly to get an interior put together for a trip we're taking this month. The design was all CAD'd up, lots of laser and forming and finally starting to put things together. Here are some teaser shots of our bench/bed combo (and the floor system I've been working on for a while too). Upholstery is in process...

bench.jpg bed.jpg

The folding motion of the bed is smooth and awesome; locks into place in both bench and bed positions for saftey. Really happy with how it's turning out. Total size (with additional bed panels in the back) is 52x80. I'm going to use this seat design in a couple upcoming E-series build outs as well.


Der Chef der Fahrzeuge
I also spy some integrated rear cubby holes... Awesome work as usual my friend.
How do you know those are cubby holes Brad? Could possibly be a feeding trough for miniature ponies which could be lashed to the L-track. :p
That's the beauty and flexibility of the L-track system in a van, the possibilities are quite endless!(camping gear, motos, snowmobiles, equipment...mini ponies!) :sombrero:

Excited to see what's next on this build!!
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Just got back from a 10 day trip through Oregon, California & Arizona with the Transit. A little over 3200 miles, mix of freeways, back roads and off road. Lovin' this van!!! Smooth and comfortable, easy to drive, lots of room to move around inside.

transit after trip1.jpg


The purpose of the trip (aside from family time and taking a small break from the non-stop work around here) was to test the driveability of the van with the lift, gearing change, larger tires. I honestly like the van a lot better now vs. stock. Feels very stable at speed and the ride is very good. Drives and handles more like a small SUV than a large van. Fully loaded with the interior and our stuff we were 7550lbs. Not heavy but you could feel the weight in the van. The Ecoboost did awesome, never felt like it was working hard and always had more go ready when I needed it. Fuel mileage was 15-ish... didn't pay much attention to it.

Off road experience was good. You can get a lot of places even with the weak factory LSD. I was really interested in getting it out in the dirt and the experience pretty much confirmed a lot of what I was already thinking of doing to make a better 4x4 conversion than what's out there. There are some weak points in the stock suspension and a few areas need to be beefed up a bit for any serious off road capability. I'm really excited to get back to the CAD workstation to work out the last few details of the 4x4 parts!
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Solid Axle? Nope, not happenin' here.

The van drives great with its current suspension. No sense in scrapping what already works well. It just needs some tweaks to fit in a few more components up front. ;)