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

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JamaicaJoe

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What make model are the new headlight housings?

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Tjhoward84

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I think this did come up before. I don't know if the Stiffler's UCAs will fit a 4wd. I know they were originally made for the Lightning crowd and all of those are RWD so I don't think these have ever been tested on a 4wd.

What I do know for sure, the original upper arms are different on a 4wd than on a 2wd.

Now, looking at the pictures, the Stiffler's arms have the ability to rotate the arm at both bushings on the framerail, and one joint that can be adjusted all the balljoint, so perhaps that, along with the fact both sides can be lengthened/shortened, means they might be able to fit a 4wd? I have never tried it or compared firsthand so I can't say for sure. Shoot me a PM, I do have a set on the shelf that I can take some measurements on and maybe if it's close you might decide it's worth ordering some to try it out?

https://www.buystifflers.com/f150LightningAdjustableFrontUpperControlArms.aspx



Well, you get a gift for one, you need to have something for the other, otherwise they get jealous of each other.

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Makes perfect sense now. I forgot you had it's matching little brother. Love both of these trucks.


I'm not a big fan of the aftermarket look either. Other than the wheels and headlights (which are replicas of OEM parts) pretty much everything, at least that you see from the outside, is OEM. The height is probably a touch lower than Ford's Thunder concept was, but it makes it easier not having to lift my groceries as much to get them in ;)

Curious, what do you think I'm going overkill on?

I, for one, think everything you have done to top notch and on point and definitely not overdone or overkill. It's exactly what I would do given the resources ($$) and knowhow. Keep it up. Absolutely love the Expy.
 
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MISTERgadget

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What make model are the new headlight housings

They're "Depo" brand replicas of 01-04 Lightning headlights, easily found on eBay or Amazon. The retrofit kit shown earlier in the thread is from TheRetrofitSource.

I, for one, think everything you have done to top notch and on point and definitely not overdone or overkill. It's exactly what I would do given the resources ($$) and knowhow. Keep it up. Absolutely love the Expy.

Thanks TJ! I ask because I know that I tend to get tunnel vision on a way of doing something, I like boucing ideas around and thinking stuff through, I know I'll get stuck on a certain way and I like the discussion.
 
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MISTERgadget

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So now the buckets and rear console go in, I still need to finalize the console brackets and put the trim pieces in, but it looks fantastic so far. Can't wait to do the front seats to match! Thanks to Chris for the great looking seats and Danny for the OEM level installation of the floor latches, it works just how Ford intended. I figured if Ford had ever sold a "Thunder", like the SVTs of the time it would only come fully loaded (my 03 Lightning literally only had 1 option, a tonneau cover). In my imagination this meant it needed to have rear captains and a console as would befit either the "mommy missile" or "executive express" it might be for buyers.

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Definitely needs some black carpet as well to complete the look :D

Finally, after what seemed like forever, the body shop finished up my wings west spoiler! I had it painted by a local body shop and mounted it with 3M double sided mounting tape. I also switched back to a stock style 3rd brake light, the clear lens LED one positioned the LEDs so they were aimed straight back assuming a stock mounting position, with the 3rd brake light is angled, that wasn't going to be visible anymore. I used Diode Dynamics LED bulbs inside the 3rd brake light.

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and a couple glamour shots of the truck with the brakes and all that for good measure :slight_smile:

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MISTERgadget

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Progress then slowed dramatically for many months... the Expedition and her siblings had a new home, and of course the honey-do list required a lot of attention.

The big win was that both of the favored children could stay inside now :Big Laugh:

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Took me a bit to get moved in and organized, you can see the motor patiently waiting for it's new home....

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One thing I did jump in to do was a full paint correction to make up for that time parked outside

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even did the roof for good measure

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I was thrilled with the results, not bad for all original, 20 year old paint.

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MISTERgadget

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I knew the engine swap was going to be involved, and I wanted to give myself the time and space to do it right.... (famous last words as little did I realize just how involved, a couple of curveballs thrown my way changed everything), so I distracted myself with a little bit of interior upgrades for the time being.

I knew that I wanted to follow the example the concept SVT Thunder set in using the Lightning interior bits.... and the school bus steering wheel in old man tan sticks out bigtime...

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While the recovered Lightning buckets, smaller 4 spoke steering wheel, and the black trim on the dash and console gave the Thunder concept a much much better look.

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So I raided my bin of leftover Lightning parts and first to go was the steering wheel. bye bye!

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Test fit looks good, but we can do more while we're here.

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Let's get the cluster out and give it some contrast!

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Forgive my eagerness to add a little bit of flair on there, I know it's a shameless upbadge!

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Cluster back in, and while you're in that far might as well take care of some other stuff...

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Added a black cluster surround that holds some of the speedhut gauges we saw earlier.... much better already

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While it was all apart I added a Sony XAV AX100 headunit, which ruins the other gauge pod I had on hand, but does let me add carplay and a backup camera to keep all the conveniences you'd expect today.

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Wheel is back on

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and now one of my favorite tricks, airbag from a Ranger/Explorer fits and has a metal Ford emblem instead of just the embossed Ford logo in the plastic. Just feels like the right way to cap it off.

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The original wheel from my 2003 Lightning was on there, and it's real nice.... but I had gotten used to the nice heft of a slightly thicker wheel like the custom thicker one with suede and leather I had made for my Lightning. I didn't want to go that far down the rabbit hole here though, so I used a leather wheel wrap kit to give it some more thickness and have both smooth and perforated sections like the Cobra and FR500 mustang wheels.

For my first time ever trying something like this, I was pretty happy with my work.

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I hid all my ugly stuff in the back

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Looks like nearly a brand new wheel about to go on

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And now I'm really thrilled with the outcome

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MISTERgadget

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Continuing with the theme of distracting myself by doodling in the margins instead of getting dirty pulling the motor....

I added door strikers from 2010-14 F150s, they use rubber isolators to hold the door still better. They made closing the door feel a lot more solid, and now the body feels better over washboard roads, expansion joints and potholes.

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and I decided to take some nice pictures and list for sale my 2.3 Whipple....

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but there was a new box that came in

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because I couldn't say no to their new release for the Lightnings and a smoking black friday sale, for less than a rebuild of my used ad pretty old 2.3 would have cost me, I went from a Gen 1 2.3 Liter Whipple, to a Gen 4 2.9 Liter....

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Best part is, the upgraded plenum I had gotten for my 2.3 was still a direct bolton for the 2.9, so I could even keep it to upgrade the newer, bigger and more efficient 2.9 when the time comes.

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and I didn't forget about getting something on the way to make up for the gauge pod I lost when going to a double DIN

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JamaicaJoe

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Did you have to paint the dash trim? If so, What kind of paint? Mine is chipping in places and clearly the paint has texture.

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MISTERgadget

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Did you have to paint the dash trim? If so, What kind of paint? Mine is chipping in places and clearly the paint has texture.

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The pieces I swapped in were all originally black from other models, so I haven't experimented with painting them myself. I know the builder of the gauge pods like the 2 I got uses SEM Color Coat for painting them.
 
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MISTERgadget

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So, the thing that finally pushed me over the edge into doing the heavy work and getting the motor in? AC in the garage!

After about a 20 point turn to get it perpendicular in the garage, the work could begin. The new motor sits nearby overseeing my progress and telling me it wants in!

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Last ever view of the engine bay as it was... totally stock. I knew (mostly) what I wanted, so I was able to resist the temptation of adding anything I thought would end up being redone... no air intakes or other stuff like that...

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Grill and bumper off to avoid any damage and make it easier to work on, fluids being drained...

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Parts pile started to grow very quickly as things came off

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Intake is off and we're getting warmer

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Headers out and they're looking a bit more seasoned this time around

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Then after undoing the transmission, it was time to say goodbye

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Other than the dirt, they don't look very different at a glance... but can't wait to see how different it'll run!

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