Stage 1. Get the van running again. Replacing the engine with a warrantied rebuild.

Stage 2. Build front Axle.

Stage 3. Install front axle.

Stage 4. Install New Rear Springs & New Sterling 10.5 Axle.

Stage 5. New Rims and Tires.

Stage 6. Install NV273 BW1356 Transfer Case, Shorten Gas Tank

Stage 7. New Bumpers,  Front and Rear.

Stage 8. Convert the interior into a high tech camper, w/ fridge, microwave, Flat Screen, small sink, TV, Dash mounted lap top computer w/ 3G internet and wifi.

Stage 9. Cross Country Road Trip.

Here’s what everything has cost so far:

VAN:

• 1997 Ford E250 Cargo Van. Engine has been dead for 2 years. Probably worth about $1000 as is.
  

PARTS:

• New Rebuilt Engine $1700.00
• Dana 60 Front Axle from a 2002 F350 Dually  $300
• NV273 Transfer Case. Bought the wrong case This one is FOR SALE $450 (or I may just save it for a rock crawler or future Jeep Project). This case is both HEAVY and heavy duty but it won’t easily mount up to my 1997 4R70W Transmission. This NV273 T case will work for some of the newer Ford van transmissions.
• 1350 Pinion Yoke $59.95
• A1 Cardone Ford F-350 Super Duty Drivers side Brake Caliper, A118B4790 $52.80
• A1 Cardone Ford F-350 Super Duty Pax Side Brake Caliper, A118B4791 $44.11
• Ford F350 4WD Brembo Brake Rotors and Pads $109.99
• NEW PAIR FORD F250 F350 EXCURSION WHEEL HUB BEARING 4X4 $152.00
• DANA 60 FRONT AXLE U JOINT SPICER 5-806X (2) $64.00
• Set of FOUR 16 X 7 WHEELS FORD F250, F350, SD EXCURSION OEM RIMS $250.00
• POR 15 ENGINE ENAMEL Chevy Orange POR15 PINT Restore $21.95
• POR-15 & BLACKCOTE KIT W/ PREP PRODUCTS – BLACK – POR15 $43.50
• Riddler Dana 60 Axle HD Diff (Differential) Cover $137.99
• Warn Premium Locking Hubs $207.00
• F81Z-1107-AA Hubs Studs  (avoid shipping cost by visiting a local ford dealership)
• F81Z1120AA Nuts for Studs (avoid shipping cost by visiting a local ford dealership)
• Moog Upper Ball Joints $90
• Moog Lower Ball Joints $110
• Timken Inner Axle Seal. Part # $22.00 each
• Spicer Outer Axle Seal. Part # $29.00 each
• FORD F81Z 4A322AA – Yellow O-ring fits behind the hub assembly $5.10 each. You will need 2 of them.
• UJoint Offroad 4×4 van Conversion Kit.  Part #: CK001 $595
• Salvage yard E250 opening side door windows and miscellaneous plastic trim $50.00
• Sterling 10.5 Ford F350 Axle on Ebay for $249.00 with $127 for shipping from Ohio. It probably needs new rotors and pads but everything else looks good.  The local salvage yard wanted $800
• New Rotors and Break Pads for the rear Sterling 10.5 $148.00 on Ebay.
• Center Console with 4 drink holders. $10.00 at the salvage yard.

TOOLS:

• KD 3316 FORD BALL JOINT CAM TOOL $20.69
• Engine Hoist $170.00
• Engine Stand $50.00
• 3/4 Large Impact Socket Kit
• 3/4 breaker bar
• 4 1/2″ Grinder Wheels $14.00 each
• Harbor Freight Ball Joint Service Kit – $49.00
• OTC Outer Seal Tool. $60.00

Shopping List – still need to find:

• F250 / F350 Front Sway Bar.
• Four 285/75/16 Tires – probably going with Bridgestone AT T/A KO’s or KUMHO’s ??? Read the reviews and look at the super low price!
• BW1356 Transfer Case from a 1992 – 1996 Ford Bronco.
• Dirt Cheap Sterling 10 1/2 Rear Axle w/ 3.73 gears.  I don’t want to pay more than $400.  I’ve found them at this price ($200 – $300 on Ebay) but shipping is another $300. None of these sellers live anywhere near Delaware and I don’t think my wife will let me drive to Florida just to pick up a truck axle. I could however tell her we were going on a short vacation and kill two birds with one stone…. UPDATE: Just purchased a Sterling 10.5 Ford F350 Axle today on Ebay for $249.00 with $127 for shipping from Ohio. It probably needs new rotors and pads but everything else looks good.

Other pieces and parts: