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Offline Foundation

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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.   :knucklehead: 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.  :facepalm:
 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. 
For no one can lay any foundation other than the one already laid, which is Jesus Christ. 1 Cor. 3:11

Offline stlaser

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Re: Excursion Cummins Build for the Mrs.
« Reply #1 on: January 30, 2020, 08:06:25 PM »
 :likebutton: :likebutton:
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Offline KensAuto

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Re: Excursion Cummins Build for the Mrs.
« Reply #2 on: January 30, 2020, 08:18:19 PM »
Your Mrs has good taste IMO.
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Offline JR

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Re: Excursion Cummins Build for the Mrs.
« Reply #3 on: January 30, 2020, 09:27:44 PM »
So far do good. Think the first bumper is overkill?
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Offline swbhobie16

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Re: Excursion Cummins Build for the Mrs.
« Reply #4 on: January 31, 2020, 09:17:42 AM »
whatever you do, don’t paint it cummins beige. that color only has a 50/50 shot at running after built/installed.  :evil: :grin:

Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #5 on: January 31, 2020, 10:38:32 AM »
Good Lord

(No really, he is a good Lord)

But Holy crap! You gonna have all this done in less than two months!  :facepalm:

Psycho...

But I like it (a lot) :wink:

Good luck, and on something this ambitious, I hope your prayer life is strong in the force!!!
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Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #6 on: January 31, 2020, 10:40:18 AM »
whatever you do, don’t paint it cummins beige. that color only has a 50/50 shot at running after built/installed.  :evil: :grin:
I concur!!!

Ford blue, chevy orange, devil black, Cat yeller' or pontiac turquoise...anything but that injection pump cloggin beige
« Last Edit: January 31, 2020, 10:40:53 AM by Flyin6 »
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Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #7 on: January 31, 2020, 10:42:04 AM »
Anyone else think that bumper on the red truck is all three kinds of ugly?

Just me???

;-)
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Offline Bigdave_185

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Re: Excursion Cummins Build for the Mrs.
« Reply #8 on: January 31, 2020, 10:37:37 PM »
I thought that was the first bumper you built for your tundra Don?


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Offline stlaser

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Re: Excursion Cummins Build for the Mrs.
« Reply #9 on: January 31, 2020, 10:45:58 PM »
I thought that was the first bumper you built for your tundra Don?


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About same weight as sq d unit.....  :evil:
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Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #10 on: February 01, 2020, 09:58:43 AM »
I thought that was the first bumper you built for your tundra Don?


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I thought that was the first bumper you built for your tundra Don?


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Shhhh,,,

Don't tell anyone!!!!!!!!
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Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #11 on: February 01, 2020, 09:59:10 AM »
I thought that was the first bumper you built for your tundra Don?


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About same weight as sq d unit.....  :evil:
Lighter probably
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Offline Foundation

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Re: Excursion Cummins Build for the Mrs.
« Reply #12 on: February 04, 2020, 04:11:32 PM »
No need to wish gentlemen, that beauty of a bumper can be yours for the asking......  :grin:
For no one can lay any foundation other than the one already laid, which is Jesus Christ. 1 Cor. 3:11

Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #13 on: February 05, 2020, 10:40:34 AM »
No need to wish gentlemen, that beauty of a bumper can be yours for the asking......  :grin:
Hollywood?
Set of the latest mad max movie??
;-)
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Offline Bigdave_185

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Re: Excursion Cummins Build for the Mrs.
« Reply #14 on: February 05, 2020, 10:59:45 AM »
I’ll pictch in shipping if you mail it to Ken


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Online dave945

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Re: Excursion Cummins Build for the Mrs.
« Reply #15 on: February 05, 2020, 12:53:51 PM »
I’ll chip in for gas if you drive down and install it on his truck while he’s sleeping. :)


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Offline TexasRedNeck

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Re: Excursion Cummins Build for the Mrs.
« Reply #16 on: February 05, 2020, 08:07:39 PM »
In


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Offline stlaser

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Re: Excursion Cummins Build for the Mrs.
« Reply #17 on: February 05, 2020, 08:35:28 PM »
In if you slap a H for president sticker on it b4 you ship.....  :evil:
trying to find new ways to annoy Ken

Offline KensAuto

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Re: Excursion Cummins Build for the Mrs.
« Reply #18 on: February 05, 2020, 09:08:08 PM »
How did I get dragged into this!
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Offline stlaser

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Re: Excursion Cummins Build for the Mrs.
« Reply #19 on: February 05, 2020, 09:21:01 PM »
How did I get dragged into this!

We couldn’t think of anyone else who could mold that horrible chunk of steel into something beautiful.....

Or who had the equipment to hang that ton of steel off the end of a truck!

  :tongue:
trying to find new ways to annoy Ken

Offline JR

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Re: Excursion Cummins Build for the Mrs.
« Reply #20 on: February 06, 2020, 12:44:47 AM »
I'll chip in for gas AND get a sticker for it, whoever runs,,,,,
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Offline TexasRedNeck

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Re: Excursion Cummins Build for the Mrs.
« Reply #21 on: February 06, 2020, 06:44:52 AM »
In if you slap a H for VICE president sticker on it b4 you ship.....  :evil:
FIFY


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Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #22 on: February 06, 2020, 12:12:56 PM »
I’ll chip in for gas if you drive down and install it on his truck while he’s sleeping. :)


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I'm in on that deal!
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Offline swbhobie16

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Re: Excursion Cummins Build for the Mrs.
« Reply #23 on: February 06, 2020, 07:55:43 PM »
thanks to all y’all  :knucklehead: ‘s the man is going to have to start ANOTHER build thread for this truck.

at the rate he’s having to think of new names for the headline, he’s losing steam and it’ll be sq d all over again! hahaha.

for his sake and the wife’s, leave the man be and let’s enjoy a speedy, single thread build of an awesome overlander  :beercheers:

Offline Bigdave_185

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Re: Excursion Cummins Build for the Mrs.
« Reply #24 on: February 06, 2020, 09:11:12 PM »
Yes mom


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Offline JR

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Re: Excursion Cummins Build for the Mrs.
« Reply #25 on: February 06, 2020, 09:20:44 PM »
Uh, no DOTing???????????????? :undecided:
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Offline Foundation

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Re: Excursion Cummins Build for the Mrs.
« Reply #26 on: February 14, 2020, 03:53:26 PM »
Baha, looks like the consensus is Ken is the man for the bumper..... now I just need someone to help me lift into the truck bed.....

It is a-going. At this point I have taken the original budget and doused it in gasoline and lit it. Becoming more painful. I am not a body guy and the guy who is gets to take all my money on this one. I. Hate. Rust. I officially own 2.5 Excursions now to make one good one. Cutting out and replacing bad spots, will take recommendations on what you all use to "neutralize" and coat the lighter stuff. Brother-in-law works for a pipeline company and has some stuff they used to coat underground pipe with that I may liberally use underneath. I have use POR15 in the past but just haven't been thrilled with it.

Engine is getting buttoned back together. Mods on it are:



PPump:
Power Driven Diesel AFC Live (in cab fueling setup)
Higher flowing delivery valves
3k governor springs (debating on dropping 4K in but not sure - opinions?)
Extended rack travel cap





Engine:
60# intake and exhaust spring
Timing bump from 12.5* to 18* (supposed to be happy medium for power and mileage)
Injectors - need to see what is in it. I have
Turbo:
Has Holset HE351 on it, was blowing oil past the seals so dropping in new cartridge with billet wheel
PDD Hot Rod Modified Cummins Lift Pump - mechanical but should be able to push needed PSI even if FASS goes down.


Suspension/Wheels/Tires

Has a 4 link coil over setup in the front
1 ton rear end with bags
Went with Rancho XS9000XL Adjustable Shocks - maybe take a leaf out of rear for ride since we have bags and can adjust shocks? Not sure yet.
34" Nitto Terra Grapplers G2s - needed to fit in garage so had to be conservative here
Pro Comp Series 69 Alloy Wheels
Replaced pretty much everything that moves in a circular motion.  :facepalm:


Interior:

Bringing everything over from the black one
Installing sound deadening
Installing a Ford Dash Kit for cleanly mounting all the necessary switches for all the go go gadgets I will want


Exterior:

Shifting from wrap to thinking I want to professionally line x it for the long haul. Any thoughts on this?

For no one can lay any foundation other than the one already laid, which is Jesus Christ. 1 Cor. 3:11

Offline TexasRedNeck

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Re: Excursion Cummins Build for the Mrs.
« Reply #27 on: February 14, 2020, 05:01:41 PM »
Wow. Bet this thing is done before the burb is finished.

I’m not a fan of bed liner on the body. Way too permanent and if you change directions later it’s a one way deal. Paint it and clear PPF is my vote or a color wrap and you can change it in 5 years.

But it’s your chicken. Pluck it how you see fit.


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Offline stlaser

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Re: Excursion Cummins Build for the Mrs.
« Reply #28 on: February 14, 2020, 05:52:12 PM »
I like the linex, with that stated not sure I would do it all over just maybe lower panels
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Offline KensAuto

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Re: Excursion Cummins Build for the Mrs.
« Reply #29 on: February 14, 2020, 07:22:35 PM »
Kinda agree with Tex and Stlaser. I like the idea of doing the lower section for rock and possibly rust protection, but wouldn't do anything unless they stick a warranty on it.
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Offline JR

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Re: Excursion Cummins Build for the Mrs.
« Reply #30 on: February 14, 2020, 08:38:16 PM »
Yep, lower section is the way to go and my plans.

You rebuild the Ppump yourself?
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Offline swbhobie16

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Re: Excursion Cummins Build for the Mrs.
« Reply #31 on: February 15, 2020, 10:31:32 AM »
my dad has 4k GSK in his. go ahead and do it now so you won’t have to later. he can regularly run it up to 2500-2700 with zero issue or even the slightest hesitation or defueling. and the thing revs faster  than a SBC. you can always have it and not use it, but if it’s not there.. it’s not even an option  :grin:

Offline Foundation

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Re: Excursion Cummins Build for the Mrs.
« Reply #32 on: May 01, 2020, 01:18:15 PM »
Phew, pretty crazy couple months. A lot going on, interesting time we are living in.

On the build: it continued to morph and lessons continue to be learned. Received the body back from the body shop and it was unusable. Long story, after meeting with body guy he agreed it was not correct. There were a lot of corners cut and honestly he just got in over his head on it. Welded on cab was not lined up, huge gaps on windows, panel bonding everywhere and more. Lost the money that was prepaid for parts and material and now have one expensive deer blind shell.

So in comes a third Excursion. I think the word is out now that some dude from Oklahoma is buying up the world's supply of Ford Excursions. At least that is how it feels to me.....

Found a V10 one out of Dallas that the owners niece had blown a coolant hose on and drove until it stopped. By the third one I am getting pretty good at picking them  :facepalm: . Very clean, no rust, really what I should have started with.....


 

Picked up the rest of the pieces from the shop they were at - a 10,000 piece puzzle that was pulled apart hastily by someone else.



And then started how I should of started (if I should of started) from the get go. Best friend and I commenced to do the swap on the back pad of the shop. Yanked out the V10 and stuck in the 12V. Toughest part was not having taken apart the original one the 12V was in it was difficult figuring out how it went back.









She runs pretty good, pulls like a freight train. Surprising power, honestly pulls like a tuned 6.7 my buddy has. The PDD AFC live control has been dyno tested to take a stock truck to over 900 ft -lbs with just the controller so I would assume we are a good ways past that with the other mods.  Need to figure out some stuff with TPS and / PCS transmission controller, doesn't want to hold gears. Pulls hard but shifts way too soon, once your 60+ she pulls hard for as long as you want. Waiting on communication cable from PCS to check out further on tranny.

HOWEVER, she is leaking oil like a stuck pig. The shop that had the motor was supposedly re-gasketed everything but she is leaking from several locations, one of which being the rear main  :cry: Highly frustrating, would have take a couple hours to re gasket it myself when it was out. My assumption is they did not have the correct tool to press in the rear main. May have to re-pull the motor to address. Not sure why leaking at other areas. Painful.

Need to install new front springs and shocks all the way around to handle the new weight. Lifted a safe wrong the other day and really tore up my back so might be a minute before I can do that. Once those are on I will put new tires and wheels on. Picture below is obviously just the new wheels and rubber rolled next to it to get an idea of final looks (albeit she will be a bit higher.) Also have a rear ranch hand I need to modify the brackets on to work.



And that where we are at for the moment. Kids love riding in it, just yell "show me the power!" the whole time.
For no one can lay any foundation other than the one already laid, which is Jesus Christ. 1 Cor. 3:11

Offline Bigdave_185

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Re: Excursion Cummins Build for the Mrs.
« Reply #33 on: May 01, 2020, 06:43:32 PM »
Looks clean and no terrible front bumper


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Offline KensAuto

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Re: Excursion Cummins Build for the Mrs.
« Reply #34 on: May 01, 2020, 10:21:09 PM »
Wow you've been busy. Looks great.
I feel your pain on the rear main. I've never had to warranty one on a Cummins yet the one I just did on my personal truck is leaking. Wish I would've painted the trans black just like the engine.
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Offline TexasRedNeck

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Re: Excursion Cummins Build for the Mrs.
« Reply #35 on: May 02, 2020, 06:05:07 AM »
Wow. Bet this thing is done before the burb is finished.

I’m not a fan of bed liner on the body. Way too permanent and if you change directions later it’s a one way deal. Paint it and clear PPF is my vote or a color wrap and you can change it in 5 years.

But it’s your chicken. Pluck it how you see fit.


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Popcorn. Did it get done before the burb?


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Offline oklawall

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Re: Excursion Cummins Build for the Mrs.
« Reply #36 on: May 02, 2020, 08:06:50 PM »
Well id you need another excursion let me know. If I remember correctly out local diesel guy had a customer that was putting a power stroke in one and ran out of money. I think he wants to sell it but would have to check to make sure

Offline JR

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Re: Excursion Cummins Build for the Mrs.
« Reply #37 on: May 03, 2020, 06:43:38 PM »
 :likebutton:
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Offline cj7ox

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Re: Excursion Cummins Build for the Mrs.
« Reply #38 on: May 04, 2020, 04:12:16 PM »
Looks good!
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Offline Foundation

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Re: Excursion Cummins Build for the Mrs.
« Reply #39 on: July 07, 2020, 03:30:18 PM »
Long time, no update. Got her close to buttoned up, still sorting out a few kinks. Dragged the trailer to a match about 4 hours away and she did well, found a few things to address but nothing major. Fixing to head out for 17 hour trip across country to Utah in the morning with her, won't be pulling anything so should just be loping along. Throwing on a new FSS as soon as it gets here today, been dying if you hit a bump just right  :facepalm:. Really the only thing I could think it would be, not much else to it. Any other ideas feel free to chime in!

Trip will consist of my wife along with a buddy and his, hoping for smooth sailing! Might have some marital disharmony if it turns into too much of an adventure. Lots of gravel ranch roads once we get up there, match is on a large private (250,000 acre) ranch so looking forward to taking in some big country that our good Father created for us. Been there once before and it is amazing.

Below is probably about how she will sit for the time being aside from adding a rear bumper. Bought a ranch hand but would need to modify to work, not sure what direction I will go. Oh, and running boards.... kinda have to climb in at the moment. I remember a time I thought running boards were dorky........ Front springs are factory X springs and rear is stock plus airbags but she sits on up there.





For no one can lay any foundation other than the one already laid, which is Jesus Christ. 1 Cor. 3:11

Offline JR

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Re: Excursion Cummins Build for the Mrs.
« Reply #40 on: July 07, 2020, 03:44:41 PM »
Need mileage reports for that trip. Hope it goes smooth, many ways!
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Offline Bigdave_185

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Re: Excursion Cummins Build for the Mrs.
« Reply #41 on: July 07, 2020, 04:12:26 PM »
Message if you need any Utah help,  here if need to be


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Offline Flyin6

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Re: Excursion Cummins Build for the Mrs.
« Reply #42 on: July 07, 2020, 08:44:01 PM »
That thing looks good and capable
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Offline TexasRedNeck

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Re: Excursion Cummins Build for the Mrs.
« Reply #43 on: July 07, 2020, 09:14:11 PM »
Nice update and its looking good.


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Offline Foundation

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Re: Excursion Cummins Build for the Mrs.
« Reply #44 on: July 09, 2020, 02:11:37 PM »
Few hours out from destination, letting a buddy drive and getting emails and things answered... figured throw a quick update!

Running good, loosing some coolant and oil. Hard to tell where on coolant as it’s slung everywhere. Not enough to be show stopper just annoying and making a mess. When hot she she starts right up but dies right a way a couple times before staying lit.... maybe not getting the solenoid pulled up all the way at first but has a brand new solenoid on it so maybe a juice issue. Literally threw a new FSS on it yesterday morning before pulling out. Next time going to watch solenoid while buddy starts.

Mileage is extremely sub par..... 12-13 but also may have to do with these 80mph speed limits. She’ll run as fast as you dare but spinning some RPMs at 85.

The leaks are driving me nuts. The gasket job the shop did on her is really hurting my feelings right now.....  should of done myself!  :knucklehead:

For no one can lay any foundation other than the one already laid, which is Jesus Christ. 1 Cor. 3:11

Offline swbhobie16

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Re: Excursion Cummins Build for the Mrs.
« Reply #45 on: July 13, 2020, 07:41:28 PM »
driver side oil leak..?