Mk7 4x4 Conversion

[fordzipper]

To all my fellow 4x4 tinkerers,
Many years ago, I came across Airthies conversion of his MK7. I was sold there and then, always wanted a 4x4 van. Time was never friendly but now I am finally on it. My base is a 2008 SWB van in reasonable condition.
We are limited here in Australia with what can be done in regards of lifting the vehicle. Also everything over a certain lift needs to be approved by a specialized engineer.

So far fabricated 50mm spacer blocks between body and subframe as well as fabricated a 72mm strut spacer. Difference only throws the suspension geometry out by 22mm, so not creating too much of an issue.
This has given me a lift measured at the guard of 85 mm on the original tires. With the new larger tires the total lift will be 110mm.

I have run into a bit of an oddity with the 50mm extension required for the steering shaft, now the subframe is 50mm lower. The shaft is of a hollow tube design not as I had expected, solid splined (extensions readily available).
I have seen some conversions getting around this by welding a section in the tube however here down under this is frowned upon by engineering.

Has anybody come across an of the shelf extension? What am I missing? Any suggestions for an elegant solution?

Cheers,
Zipper

[blfmtriv]

hi zipper, i just raise mine only 50mm on the front suspension and the camber is well out, how much pain is it to raise the frame and sub chassis,.
its a good project what are you going to use for the 4x4 doner? blfmtriv, Darwin

[fordzipper]

Hi blfmtriv,
Thanks for your reply. So far spacing the suspension frame has been fairly simple. We build some very solid 50mm spacers using 10mm plate. Getting the front suspension bolts out took some doing as they are fixed in a frame box section during manufacture. Needed to do this to install longer ones. If keeping it as 2wd, then a well made spacer for the gearbox mount should do it. I haven't got as far as the drive shaft as I am going 4wd so will need to make a crossmember for this. I work FIFO and am out at the moment, I'll upload some pics when back home.

The only issue is the extension of the steering shaft. I have drawn up a spacer in cad and requested a quote for CNC manufacture. If this turns out too expensive then I'll have to buy a used steering column, diagonally cut a section off, weld and sleeve it. I'll let you know the outcome.

My lift will only relatively throw everything out by 22mm. If the camber is way out, then we will modify the strut lift something like the Traxda strut lifts available in USA.

As to what to use it for, it's something I have wanted to build for 40 years....lol. However it turns out, it will be tough

Thanks again for your interest.
FordZipper, Brisbane, AU

[fordzipper]

IMG_20260622_095736348.jpg

Hi Team,

Still battling with this problem. I saw a lot of reads on my previous question but single reply.
Am I the only nutcase?

See above a 3D print of the item required. 50mm steering shaft extension. Have had a quotation back. To make a single one $A800 by CNC or make 5 units for $A1300.

Any other interested parties in this?

Cheers
FordZipper, Brisbane, AU

[blfmtriv]

i had spacers made for my 4x4 sprinter cost me less than $100 a piece from melbourne,cheap as why cant you make it in alloy, and shop it around, thanks for the tip on the camber alignment, i,m also going to upsize the tyres, maybe put a winch on, as i,m agreeance with you on 4x4, my sprinter is 4x4 and theres nothing better when going full off road ,Cheers,
Darwin / Julatten FNQ

[blfmtriv]

hi, FORD ZIPPER, i,ve been thinking of what your doing, even tho i haven't committed yet to lifting it by the body, i,m intensley interested in it, can you give me some idea what your cost is so far and what needed to be lenghtened for this project to work, i,m nt and FNQ based so i need a bigger higher vehicle for all the wet seasons, my vehicle is a crew cab dually 2.4tdci