"Thunder" 1998 Expedition Build Thread .... fixed pics!!

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MISTERgadget

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So while the paint cured in the garage... hi ho, hi ho, it's off to find parts we go!

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I had decided on converting everything to 99+ wiring with the digital odo cluster, mainly to be able to use the Lightning ECU.

Recap of the brainstorming on my last post, I already had these parts:

  • 1999 Lightning Engine Bay/Main Fusebox harness
  • 1999 Lightning Engine and transmission harnesses
  • 2003 Lightning ECU and Instrument Cluster
So, my hypothesis was, get the newer model dash harness and all the boxes attached to it, and that would let me use the newer PCM and all that. Yeah, pulling the dash would suck, but for this type of project, how bad could it be? (little did I realize...)

Wish I had gotten some "before" pictures but it looks like the camera only came out once things were underway. Found a 2000 XLT at the junkyard and it seemed like the perfect donor, my 1998 had manual AC as well, so this seemed just right.

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Getting all the good stuff out!

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I was happy we got all this out in just under 4 hours.

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Was pretty much stripped bare after I was finished. Got the full dash harness, GEM/Fusebox, a half dozen other boxes and modules, and the security box and portions of the door harness.

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Back at the garage, I got the fittings in the back of the heads installed for the coolant mod.

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A -10an hose will connect the two. In the factory configuration, coolant flows out of the back of the passenger side head only and the driver side has a deadhead. In theory, connecting the two should help coolant flow out the back of the driver head and prevent any hot spots of coolant.

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So I went to check on how things were going at the bodyshop, and the engine bay and frontend was all prepped and ready for paint.

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In the meantime, now that I knew everything was going to be the 99+ style bracketry in the engine bay, I was able to send all of those bits and pieces off to get powdercoated. I went with a silver vein finish with a clearcoat on top for extra durability. I really like how it hides imperfections with the texture of it too.

You can see in these pictures the AutoFab engine and transmission mounts that will be going on were among the parts that got powdercoated.

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I had nuts welded on to this bracket before coating it, so it would use M6 bolts to hold it together. Gave me more options other than the coarse thread OE sheetmetal screws.

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Oil and coolant manifold was PC'ed satin black, along with all the header panel and hood latch brackets, and the wiper arms.

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My Conroy Fab Trans crossmember was also PC'ed satin black (In hindsight I kinda wish I had done the silver vein on this one, oh well)

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I'm happy with how they complement each other all put together.

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Lots of new fasteners in for reassembly as well.

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We get to skip waiting on the bodyshop since this thread is being redone now to fix pics, and it goes from primed to finished in just minutes!

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Brought it home and had to muscle it back into the garage. I'm not at the level of trailer ninja to line it up perfect to drop it right into a parking spot, but this was close enough for me.

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The framerails and the 20 year old factory goop stuck out pretty bad, and half of that came off when I pressure washed the bay, so everything that was in sight got wire wheeled, then a coat of primer and satin black.

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Front fenders went back on, with some stainless allen bolts and anodized washers

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I couldn't help myself to start mocking up all the other bracketry to see how it would look as well

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In another area of the garage, the harness from our 00 Expedition XLT donor was going onto my dash

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Started putting my motor mounts on too and did a double take....

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oh that sneaky little...

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is this where you've been hiding the whole time? :bawl:

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DSF1

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Just wondering if the headers you used were custom bent or originally made for f150 fitment? Can't imagine you found a set actually made for expedition. Have an '11 and was hoping to do something similar. Would have PMd you but can't find the tab on my phone app
 
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They’re a 97-03 F150 fitment. Since the Expedition is the same from the B-pillar forward they’re a bolt on.
 

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Did you have any rust in the radiator support bracket. If so how did you deal with it?

Any problems with leaks around the windshield or rear fixed window seals?

Mine is a Burgundy Florida car and the top paint is pretty baked out. I am considering an entire repaint and mechanical restoration of the vehicle. I have 93K on mine. Any engine mods will be bolt on.

Just would like to enjoy it a few more years.

Seeing as the new models lack a V8 and are hideously complex and expensive, restorations make sense.

25% of my toolbox are wrenches and sockets found in the street or under my hood left by careless mechanics.



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rjdelp7

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The framerails and the 20 year old factory goop stuck out pretty bad, and half of that came off when I pressure washed the bay, so everything that was in sight got wire wheeled, then a coat of primer and satin black.

IMG_2959.jpg

IMG_2963.jpg

IMG_2964.jpg

Front fenders went back on, with some stainless allen bolts and anodized washers

IMG_2956.jpg

I couldn't help myself to start mocking up all the other bracketry to see how it would look as well

IMG_2968.jpg

IMG_2965.jpg

In another area of the garage, the harness from our 00 Expedition XLT donor was going onto my dash

IMG_2991.jpg

Started putting my motor mounts on too and did a double take....

IMG_3026.jpg

oh that sneaky little...

IMG_3027.jpg


is this where you've been hiding the whole time? :bawl:

IMG_3030.jpg
I found a factory subwoofer at the local pull a part for $7. Are all the 2000/1st gen models, pre wired for the Sub or do they use a different harness. I am only asking, because I see you just pulled the harness.
 
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