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Build Threads / Excursion Cummins Build for the Mrs.
« on: January 30, 2020, 07:00:03 PM »
New thread for the Excursion build.... still thinking of name but she will speak to us I am sure.
Warning: I have read and benefited much from some of the build threads on here that are highly detailed and documented. This unfortunately will not be one of them as it will be a pretty darn fast build as the deadline is early March for a camping trip to Moab. As mentioned in previous thread - this will either go good or poorly for marital harmony, not a whole lot of room in-between. The results will be tested on a 28 hour round trip in 5 weeks.
Goal of project is to build a family friendly towing rig to take across country to different events we attend throughout the year.
Purchased two Excursion for the project. The first is a 2000 with a 94/95 160hp P-Pump 12V already installed. This one has all the right parts but has not been treated kindly. Ran strong, probably has some pump work done as well as injectors and a HX40 turbo. Tough to know exactly as the guy I bought her from was not the one that originally built her.
Second one was a "clean" gasser with a 198K on the clock. Turned out to be much less "clean" than I had thought once we dug in. Mechanically sound and has clean history but had some used car lot tricks underneath to cover up a bunch of rust on the body. Had to drive a few hours to pick it up and looked it over at dusk with a flashlight, lesson learned.
Bright side is it still had more in usable parts on her for the build than what I paid. Just a bummer as it made the project much tougher than swapping power train into this one.
Pulled them both in, evaluated and determined a game plan.
- Red one's body is actually in better shape, going to require rust repair but manageable with using combination of doors and parts between the two. Will have to find cab corners, have them coming from out of state.
-Full mechanical shakedown on Red.
Going through all suspension, brakes drive line and replacing what is needed. Which is most of it - wheel bearings, rotors/pads/calipers, lines, shocks, ect ect.
Pulling motor and transmission for inspection and re -gasketing. Advancing the timing while out along with installing 60lb valve spring.
P Pump is getting bigger delivery valves, higher governor springs, AFC Live in cab fuel control and a higher performance lift pump to hopefully push the needed fuel pressure. Couple other tweaks on pump.
Whoever gave the previous owner green paint needs to be arrested. Just my opinion...... Will be getting painted gunmetal gray.
Doing a full interior swap over from the black one so red's interior had to go!
Have done all the suspension/brakes/hubs/wheel bearings with the exception of shocks, those haven't arrived yet. Took red to body shop to get some rust repaired along with prep for wrap. Going to try a wrap on it and see what we think. This is the color the Mrs. would like it wrapped. Also sold the current wheels and bought some matte black simple 17" pro comps to go back on.
Will be tearing apart motor and trans tomorrow. Hope to find all good news! Would be refreshing, have found some surprises to be sure!
Oh, and yes, I got upgraded tow mirrors.
Warning: I have read and benefited much from some of the build threads on here that are highly detailed and documented. This unfortunately will not be one of them as it will be a pretty darn fast build as the deadline is early March for a camping trip to Moab. As mentioned in previous thread - this will either go good or poorly for marital harmony, not a whole lot of room in-between. The results will be tested on a 28 hour round trip in 5 weeks.
Goal of project is to build a family friendly towing rig to take across country to different events we attend throughout the year.
Purchased two Excursion for the project. The first is a 2000 with a 94/95 160hp P-Pump 12V already installed. This one has all the right parts but has not been treated kindly. Ran strong, probably has some pump work done as well as injectors and a HX40 turbo. Tough to know exactly as the guy I bought her from was not the one that originally built her.
Second one was a "clean" gasser with a 198K on the clock. Turned out to be much less "clean" than I had thought once we dug in. Mechanically sound and has clean history but had some used car lot tricks underneath to cover up a bunch of rust on the body. Had to drive a few hours to pick it up and looked it over at dusk with a flashlight, lesson learned.
Bright side is it still had more in usable parts on her for the build than what I paid. Just a bummer as it made the project much tougher than swapping power train into this one. Pulled them both in, evaluated and determined a game plan.
- Red one's body is actually in better shape, going to require rust repair but manageable with using combination of doors and parts between the two. Will have to find cab corners, have them coming from out of state.
-Full mechanical shakedown on Red.
Going through all suspension, brakes drive line and replacing what is needed. Which is most of it - wheel bearings, rotors/pads/calipers, lines, shocks, ect ect.
Pulling motor and transmission for inspection and re -gasketing. Advancing the timing while out along with installing 60lb valve spring.
P Pump is getting bigger delivery valves, higher governor springs, AFC Live in cab fuel control and a higher performance lift pump to hopefully push the needed fuel pressure. Couple other tweaks on pump.
Whoever gave the previous owner green paint needs to be arrested. Just my opinion...... Will be getting painted gunmetal gray.
Doing a full interior swap over from the black one so red's interior had to go!
Have done all the suspension/brakes/hubs/wheel bearings with the exception of shocks, those haven't arrived yet. Took red to body shop to get some rust repaired along with prep for wrap. Going to try a wrap on it and see what we think. This is the color the Mrs. would like it wrapped. Also sold the current wheels and bought some matte black simple 17" pro comps to go back on.
Will be tearing apart motor and trans tomorrow. Hope to find all good news! Would be refreshing, have found some surprises to be sure!
Oh, and yes, I got upgraded tow mirrors.
$$ and we used it for a few matches before I saw this one for sale a few hours away. 2004 model, never really used. Literally had one trip to Sturgis on it and then parked. 
