Ford E250 Overland Van Build with 4×4 Conversion & Lockers
For a fan of off-road camping and overlanding lifestyle, it’s hard to find a better vehicle than a Ford E-series van because of its huge interior to organize the living space protected from the elements and nearly endless potential for off-road modifications.
This white lifted E250 is a perfect example of a versatile overland van build with truly remarkable off-road capabilities gained with a help of wisely selected upgrades.
Off-road Modifications
Ford E-Series vans don’t come equipped with 4×4 drivetrain from the factory, however companies like U-joint Off-road specialize in 4×4 conversions which allow you to swap Dana 60 front axles and gain all the features of similar four-wheel drive trucks and even more.
This is the route the owner of this white E-250 van decided to go with his own build, installing a U-joint Off-road 6-inch lift kit. Along with Dana 60 front axles, he also opted for the front and rear air lockers and new Bilstein 5100 shocks with rebuilt leaf packs.
Thanks to the added space in the wheel wells, he installed 35-inch Nitto Ridge Grappler tires along with a full-size spare mounted on the back.
Of course, the size and weight of a full-size van put some limitations on the off-road capabilities of this vehicle, but with improved ground clearance, 35″ tires, higher approach and departure angles, and front and rear lockers, this van becomes even more capable than many traditional 4x4s with aftermarket upgrades.
Off-roading always implies extensive abuse, so improving body protection is essential for such activities. The owner installed a front low-profile bumper, Aluminess rear bumper with storage swing box and tire carrier, and skid plates to improve underbody protection. Air chucks on the front and rear bumpers along with an ARB dual air compressor allow airing up and down on the go without leaving the van, which is super handy on complex trails.
Among the lighting add-ons are LED fog lights, hood-mounted ditch lights, and a 40-inch LED light bar mounted above the windshield.
Living Space
After completing the off-road preparation, it was time to build out the living space. One of the biggest upgrades is the Sportsmobile electric pop-up top, which allows standing height inside the van and provides additional sleeping space. An Aluminess roof rack with 280W solar panels sits on top of the van.
Interior modifications include a custom steel frame with single-piece wooden kitchen counter, 25-gallon water tank, undermount sink with water pump, and a closet. An additional bench with Paco pad provides a sleeping spot for one person in addition to the double bed in the pop-top.
Other enhancements include vinyl plank wood floor, Dometic CRX 110 fridge, Dometic propane stove with a five-pound propane tank in the swing box, propane instant hot shower, and many other upgrades for convenience.
USB and cigarette lighter-style plugs throughout the cabin allow charging various devices and powering appliances.
List of Mods & Upgrades
Engine
- 5.4 L V8 with 5 Star Tune town tune loaded, 4.56 gear ratio
Suspension
- Ujoint Offroad 6″ kit
- Dana 60 front axle
- Front and rear air lockers
- New Bilstein 5100 shocks and rebuilt leaf packs
Wheels
- New Nitto Ridge Grappler 35″ tires – spare is a 315 BFG T/A KO2
Exterior
- Sportsmobile electric pop top
- Aluminess rear bumper with storage / swing box / tire carrier
- Fog lights
- Ditch light
- Rear lights (all on Auxbeam controller)
- Aux trans fluid cooler
- ARB dual air compressor + tank + Kleinn 2-trumpet air horn under driver side
- Warn locking hubs
- ARB diff covers
- Flowmaster exhaust
- MagHytec deep finned transmission pan
- Incudes 1UP 2″ Super Duty single bike mount (with matching keyed locks, hitch extender + stabilizer, 1UP Rack Stash, 10′ Kryptonite Bike Lock, spare keys)
- Carr Hoop steps
- Talon on left side barn door to hold it open
- 2 x gas rotopax (1 on top and 1 on back of swing box)
- ARB manual awning
- Plastic folding step
Interior
- Custom 1×1 steal frame interior with single piece wooden kitchen counter
- 25gal water tank
- Under-mount sink
- Water pump, closet
- Bench with Paco pad that sleeps 1 in addition to the double bed in the pop top
- Passenger swivel seat
- Neoprene seat covers
- Vinyl plank wood floor
- 12v Dometic crx 110 fridge
- Dometic propane stove (5lb propane tank in swing box)
- Flip out window on driver side
- Propane instant hot shower in garage
- 3 x full size Sidio crates under bench
- Custom baltic birch drawers on heavy duty sliders with locks in kitchen
- Trans temp gauge
- Lots of USB and cig lighter style plugs throughout
- Magnetic bottle opener
- Radius Outfitters trash bag with custom 3D printed lid
- Passenger seat-back organizer
- Killmat + new vinyl floor in cab
- Metal Best Made first aid kit
- Fire extinguisher
All other Upgrades
- Victron Lynx distribution
- PROwatt 2000w inverter
- Blue Sky Solar Boost 3000i charge controller
- Renogy battery monitor
- Blue Seas ML-ACR Charge relay with custom run circuit mod (connected to Aux Beam controller in cab to charge while driving)
- 12V distribution in garage and behind fridge
- Hidden LED strip mood lights
- LED under body to light van side entry
- Aux beam controller mounted in cab on custom 3D print mount with 2 x AMPS pattern mounts (one for phone, one for Aux beam) and Bluetooth control knob
- 1 lock box in cab
- 1 safe mounted to floor under bench
- 5″ Ram tough-track on dog house for gps (etc)
- Comes with completely stocked kitchen (including plates, bowls, cups, cookware, coffee kit TONS of accesories and a Wustof chef’s knife)
- Recovery gear (straps, shackles, new GoTreads XL, jack, stand, tire tools, folding shovel, etc)
- Also comes with tool kit, spare parts, fuses, as well as air tools (hoses, chucks, connectors, accessories)
Conclusion
All these modifications make this E-250 perfectly suitable for full-time van life off the grid and tackling extreme off-road trails. This build perfectly blends the off-road capabilities of a dedicated 4×4 like a Jeep Wrangler Rubicon with a spacious and versatile interior of a camper.
