Upgrade Complete_New Photos

[donl]

A while back I posted my plan to "restore/upgrade" my '03 4.6L Expy in lieu of replacing it after only 154K miles. The plan included 4.10 gears, shorty headers, CAI, underdrive pulleys, electric fans and 5 Star tune to pull it all together. Had some issues along the way with header fitment and the electric fan install which were all over come; issues and solutions were posted in previous threads. The plan also included some cosmetic changes, more of the "restore" nature which included new 22" Foose wheels, 285/45 Michelins, all dents, dings and scratches removed, new paint, new steering wheel and recovering the front driver and passenger seats. The vehicle had already been lowered with an Eibach springs, sway bars and Bilstein shocks. The OEM radio has been replaced with the latest Sony unit and better speakers with hands free coms, navigation and Android Auto and Car Play for voice activated operation; review camera is going to be installed next week.

The original painting of the plastic door and bumper moldings was supposed to be gray but had more blue than I wanted so I had them repainted matt black; much better. Check it out. One picture with the Liquid Metal 20" Wingman wheels just before installing the Foose 22"ers and one with the 22" Foose wheels, both with the "grey" moldings. The other two are after the molding repaint.

Thanks to the members that assisted in answering questions and making suggestions as I worked through the project. All in all, very good decision. I have always loved this old bucket and with the changes, the attraction is still there. Very good outcome.

 

[Cooper]

Very motivating bro! Where are those rocker panel close ups lol

 

[donl]

Very motivating bro! Where are those rocker panel close ups lol

Which do you want; just the door/fender panels?

 

[Cooper]

The driver/pass rockers a usually rushed out. just funning around.

 

[donl]

The driver/pass rockers a usually rushed out. just funning around.

South Texas, no rust.

 

[Adieu]

Shiny

How much did the paint job cost?

 

[gtncpa]

Very very nice!

 

[donl]

Shiny, how much did the paint job cost?

$5300. The "paint" job included the R/R of every piece that could be removed from the vehicle, i.e., head lights, tall lights, grill, door side panels, roof rack, etc. to minimize taping. Also included some body work to remove all dents, dings and scratches. Once that was done, all surfaces were wet sanded followed by three base coats of the original black, painting the side panels and bumpers which were a faded gray (had to paint them twice as th photos show), four clear coats finished with another wet sand and buff. Took 6 weeks start to finish.

 

[Cooper]

Wow man you took it to the max! Looks great hella ob done!

 

[Ron1978]

Great looking ride you have!!!

 

[yockmyer]

Very, very nice!!

 

[ExplorerTom]

Nice.

Makes me feel less crazy for wanting to spend money on mine.

How are you liking the 4.10 gears?

 

[Grey ghost]

Your paint job should make the factory job look like total garbage. Very nice job.

 

[Rockclutch]

Excellent bodywork and paint, must have been many hours spent!

Sent from my LG-H872 using Tapatalk

 

[donl]

Nice.

Makes me feel less crazy for wanting to spend money on mine.

How are you liking the 4.10 gears?

I have been traveling for the last few months; out of the country and I can't remember if I replied to your question on the 4.10 gears or not, so apologies for redundancy if I have but did not want to ignore your question.

Short answer is that I am very happy with the 4.10 gear setup. Hardly noticeable under normal driving but very noticeable under hard acceleration. City fuel economy is the same as long as I avoid hard acceleration away from every light; have not taken a long highway cruise so can't comment on affect on highway fuel economy. The 5 Star tune has the trans kicking down to the first gear earlier than the OEM tune; different but keeps the engine in an rpm range that facilitates taking off again; I like the kick down.

I spent about $10K on the total project (half was body work and paint) and although I really like the 2019 Expy, couldn't see spending $70K for a big SUV with the Eco Boost. I will drive the old one and repair/replace whatever comes my way. I do plan to get it on a dyno sometime soon and see wha the mechanical mods did for power. At 160K miles I expect a motor rebuild or crate motor is in the future which will provide the opportunity for more aggressive performance modifications.