2003 Expedition Face Lift Begins

[Vancouver Bob]

I have the EL extended length size expedition. I've got 20" wheels and 275 55R 20 tires on it now. It's mostly a highway cruiser so I don't want to go with tires that make a lot of noise. I had some on my last Expedition and they drove us crazy on our trips.

Yes, that's exactly why I went with the RT's vs the MT's. I love the look of the MT's but I've read/heard a lot of talk about the noise and the feel. I love the way my Expedition drives and the level kit didn't change that. We'll see how she feels with the bigger and heavier tires on.

 

[Vancouver Bob]

Back from a day at the welder. The owner is a tug boat captain and he was out on the boat (for two weeks) but his son and the fab guy/welder were both there. All three are really nice guys and Richard (welder) did a great job coming up with a mount that we both were happy with. Considered front mounts, side mounts and top/bottom mounts. We went with top/bottom because it would make installation/removal easier since the brackets would hold the weight of the bumper while it was being slid into position and bolts mounted. He took the time to make sure the bumper was positioned just right, made sure I was happy with how it looked before tack welding things in place.

 

[Vancouver Bob]

Once tack welded, we then took it off and he welded it. We were planning on two long bolts from top to bottom of the frame beams but once things were tacked in place we noticed that this wouldn't work because the top and bottom surfaces of the beams were not parallel. Thought going with four individual bolts would be best but there was no way to get the nuts/washers on the inside of the beam because the opening (on the front of the beam) is too far forward into the bumper and no way to get a hand in there. So I'm going to bore a hole into the side of the beam large enough to get the washer/bolt and a finger in there. Here are a few pics of today's effort...



He added gussets both top and bottom for extra strength...





The frame beam is an interesting thing. It's like a flat piece of metal that was folded into a beam. So the top of the beam is single thickness while the bottom, where the two ends overlap, is double. The original tow hooks mount to the bottom where the metal is doubled up. so I asked Richard to add a plate to the top, where it's single thickness, to beef things up. All it needs now is some holes. I'm also thinking of having them put a little finishing touch on the ends where the bumper meets the trim.

 

[ExpeditionAndy]

Wow that is a lot of work! The bumper looked good sitting up there. Where are you going to have them add the extra metal pieces?

 

[Vancouver Bob]

Not bolted on yet but this is what she'll look like when it is... it's basically just resting on the mounting plates here.

 

[Vancouver Bob]

Wow that is a lot of work! The bumper looked good sitting up there. Where are you going to have them add the extra metal pieces?

The ends of the bumper where it comes up to the trim. It's doesn't tie in well. Not a big deal but just one of those little details.

 

[Vancouver Bob]

The ends of the bumper where it comes up to the trim. It's doesn't tie in well. Not a big deal but just one of those little details.

I still have the trim piece that I cut off of there.... I'll see if I can't cut it to fit.

 

[ExpeditionAndy]

The ends of the bumper where it comes up to the trim. It's doesn't tie in well. Not a big deal but just one of those little details.

I see what you mean it looks like they were off on their angles.

 

[Vancouver Bob]

Got the new shoes on today. Had to do a little trimming of the running boards but that was it. Drove it around a bit and the drive felt good. Didn't take it on the freeway. Yesterday when I went up to Kelso to have the welding done, I had a bit of a vibration in the steering wheel up around 65-70. I'm curious to see if that went away... I'd like to be able to blame it on wheel balance of the old setup.

 

[ExpeditionAndy]

Got the new shoes on today. Had to do a little trimming of the running boards but that was it. Drove it around a bit and the drive felt good. Didn't take it on the freeway. Yesterday when I went up to Kelso to have the welding done, I had a bit of a vibration in the steering wheel up around 65-70. I'm curious to see if that went away... I'd like to be able to blame it on wheel balance of the old setup.

Looks good. I wonder if the vibration has anything to do with the bumper not being on it to block the wind.

 

[Vancouver Bob]

It was a definite vibration in the steering wheel. Perhaps flat spots on the tires after sitting for so long? But with the bumper gone I did secure all the flaps (bottom of radiator and wheel wells) with bungee cords so that they would keep things from flying into the radiator but also to keep them from getting ripped to shreds by the wind.

 

[ExpeditionAndy]

It was a definite vibration in the steering wheel. Perhaps flat spots on the tires after sitting for so long? But with the bumper gone I did secure all the flaps (bottom of radiator and wheel wells) with bungee cords so that they would keep things from flying into the radiator but also to keep them from getting ripped to shreds by the wind.

I know when it's cold and my truck sits for 2 or 3 days, I have flat spots until the tires heat up. It can take up to 10 minutes when it is very cold outside.

 

[PHIL CLACK]

Got the new shoes on today. Had to do a little trimming of the running boards but that was it. Drove it around a bit and the drive felt good. Didn't take it on the freeway. Yesterday when I went up to Kelso to have the welding done, I had a bit of a vibration in the steering wheel up around 65-70. I'm curious to see if that went away... I'd like to be able to blame it on wheel balance of the old setup.

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Looks like the level kit shortened the wheel base a bit....I wonder is the turn radius improved?
Great looking truck!

Sent from my LG-H872 using Tapatalk

 

[Big Brian]

doesn't it bother you that the rear wheel is not centered in the wheel well?

that would drive me crazy

 

[Habbibie]

doesn't it bother you that the rear wheel is not centered in the wheel well?

WHY IS THAT?!! Anyone?!

 

[ExpeditionAndy]

WHY IS THAT?!! Anyone?!

Geometry. As your raise the vehicle the trailing arm pivots and swings down moving the wheel in an arc, moving it closer to the front of the opening. The only solution is to install a longer trailing arm and probably a longer driveshaft if your want to center the wheel in the wheel well.

 

[Big Brian]

I know why, I just don't like it

my opinion only...

 

[JoshA77]

Got the new shoes on today. Had to do a little trimming of the running boards but that was it. Drove it around a bit and the drive felt good. Didn't take it on the freeway. Yesterday when I went up to Kelso to have the welding done, I had a bit of a vibration in the steering wheel up around 65-70. I'm curious to see if that went away... I'd like to be able to blame it on wheel balance of the old setup.

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Rig is looking mighty fine Bob! I like those fuel wheels.

 

[John Christopher]

I have been following your build and have a few questions. Why did you pick that yellow color for the bumper. It doesn't match the trim. Also what are you gaining my installing that bumper. Seems like a lot of work. Thanks

 

[ExplorerTom]

Why did you pick that yellow color for the bumper.

It's the color of the primer.

Also what are you gaining my installing that bumper.

If this one has to be explained, you won't get it.