Condo Garage Bullet-Proofing

[H8T2W8T]

I started my 2005 Excursion bullet-proofing project. Catch is that this will all be done in my condo garage which is roughly 12'x26' before any of my shelves, tool boxes, etc, and oh by the way a 19' land yacht. I've read the other threads on the subject and I don't plan to do a step by step write. Rather I hope to keep a picture timeline on my work. (Mainly so I know how to put it back together-) This is my first diesel vehicle and first time turning a wrench on one. I'm not new to doing this type of work as you'll see my last project in the last picture for tonight.

Installing: BPD External Oil Cooler kit and Sinister Diesel Master Solution Kit with new EGR cooler.

I'm only using basic hand tools and a 1/2" impact wrench. Wish me luck.


Got the grill off and showing how much space I'm working with in front on the Ex. The goodies are peeking in from the shelf on the left.



Grill off. You can see the massive space I am working in, even on the sides.



Better angle of the limited space.



Took the bumper off. Planning on removing everything from the front end to make more space once I dig into the bread and butter of the project. My helper removing the headlights.



My helper doing something...Does it matter? Whatever she's doing she looks good doing it BTW-the ramps are used instead of stilts to see over the front end.



Pulling all the coolers to make space for later knuckle busting action.



No comment required.Can't say what happened after this pic was taken.



3 hours into it and dinner is served. I'll start again tomorrow. Got the front end pretty much removed to the point I wanted.



Parts are starting to stack up. Radiator and Intercooler.



The opposite side of the Ex. Tight space, but just enough for the bumper, AC condenser, and Trans cooler.



Tight space again.



Last one for the night. My last project backed up to my new project.

[redlinedsix]

Looks fun. Just sold my wife on the idea of tearing into mine as well. Got to do some shopping first..who are you taking your heads too?

[H8T2W8T]

No idea yet. Not sure if I need to. I know that goes against most advice here, but minus the BPD oil cooler, I am doing all of this as a preemptive step. The Ex has no other problems, but I figured while I was in there I might as well knock out what I will eventually do down the road.

[HarvestingInternationally]

looking good so far good luck

[onebadcoastie]

If you take the crossmember off that the hood latch is attached to, it will help tremendously!!

I'm currently doing mine as well and this is what I did...

If you look at the below picture, you'll notice that crossmember is off....

[superBADduty]

Great job so far!

[Korx]

Looking good! Keep up the good work and keep us posted. I plan on tearing into mine pretty soon as well.

I would recommend taking you heads to the machine shop to at least get checked out before putting them back on.. It's a small price to pay in the whole realm of things and is good insurance to be sure that the job gets done right.

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[Guthrie PSD]

Cool thread, always love these DIY bulletproofing jobs.


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[Lilpooh]

We like stories with pics!!!!


IMO, when you remove the heads, send them to be checked.


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[Karls03]

I assume that the heads are coming off (Sinister Diesel Master Solution Kit). I read that if you lift up the transmission off it's cross member about an inch or two, it will provide the clearance to remove the aft two driver side bolts.