99 Expy 4x4 Upgrades Completed

[Coey326]

So we are planning to travel across the United States,Mexico and Belize. Maybe further sometime in the future but that is all this year. I have done a lot of upgrades to my Expy to make it durable,functional, and safe. The biggest upgrade was a brand new crate motor. I had the head gasket leak and decided to just replace the whole engine. I also added dual batteries,brush guard with LED light bar,hidden winch,roof basket(with LED light bar,box,6 4" lights,shovel,high lift jack and axe),new tires,all new suspension,changes out all fluids,new brakes,all new headlights,taillights and fog lights and Im sure theres more but I can't think of it right now. If I have done anything you are curious about I can do a write up on that on item. So here is a before and after picture.

 

[ExplorerTom]

Where'd you find room to put the 2nd battery?

Looks like a proper vehicle now. That before picture was pretty pedestrian looking.

 

[Coey326]

It was actually really easy. I just removed the original battery box and replaced it with this one.

https://www.amazon.com/gp/product/B012URFNL6/ref=oh_aui_detailpage_o02_s00?ie=UTF8&psc=1

Since Optima batteries are smaller and sit different, it fit righting the same spot with a little bit of wiggling. The only issue is there is a little black box behind the factory battery box. I just moved it to the front and attached it to the new battery box. You can see it zip tied between the batteries and the TRUE isolator in the picture.

 

[Tavy]

Put some skid plates to protect your under carriage. I just installed a RCI skid plates on my 2011 EXPY check it out.

 

[Coey326]

Looks great and thanks. I was just thinking of where to get those. Did you get from their website or somewhere else?

 

[Tavy]

Ordered them directly from RCI website. Also since you will be traveling cross country it may be a good idea to install a HF/VHF/UHF ham radio as part of your coms equipment.

 

[Coey326]

I will look into that. Sounds like a great idea. Thanks

 

[1997SCEBFEX]

nice.

recommend mud guards as well as you'll be traveling on many road surfaces.

good luck and post up pics of your expedition, on your trek.

 

[hartsemperfi]

Love it ready for watever

 

[whitelightning99]

looks nice Trisc

 

[Clemson82]

Just curious, what can / will you use the 2nd battery for? Is it connected to an inverter? Is there any impact on the charging system, or can you just keep everything else stock? That's a great idea, looks good.

 

[Coey326]

It is used to run the winch and all the off road accessories. I have an isolator hooked to my setup. It decides which battery is getting charged so that you don't put any strain on your system. it charges the main(redtop) battery first. When it fully charged it switches to charge the accessory(yellow top) battery. That way you will always have starting power

 

[poorboy1964]

Looking great I like the second battery with solenoid I did that in an old truck with camper It work very well

 

[Tocapet]

If you do the HF/VHF/UHF ham radio setup, be advised that you will need licenses to operate it in each country you visit. Not expensive, but must pass exams to get them. Also, the multiband, multimode radios are not cheap. By the time you get the radio with all the antennas installed, you will have easily spent over $10K. Then there's the matter of crossing the borders with it.

Tom Pettit, KC5PA

 

[Flying_Finn]

That is a gorgeous looking 99. Nice work. It gives me increased hope and ideas for my '98 and what I want to do to it. Not only to increase its lifespan but also to make it even more capable.

 

[2000 expy owner]

I'm working on some of the same mods. Need to get those skid plates. Already dented my transmission pan

 

[knewblewkorvett]

Sweet!

 

[Texpedition45]

I'm working on some of the same mods. Need to get those skid plates. Already dented my transmission panView attachment 19326

From where will you get your skidplates? I'm in the same boat.

 

[Coey326]

I was referred to RCI for skid plates. So I will do a little research and start there.

 

[zildjianavedis]

Looks great! I hope to start modding my expy soon!