VERY cool Kevin! I had a 2004 V8 (yes, they made 5.4 V8 Excursions. No idea why, as it was a monster terd) that was definitely one of my favorite rigs. The 44 gallon factory fuel capacity was incredible, even with the 10-11 mpg! For much of my research I ended up on the Excursion sub forum of
https://www.ford-trucks.com/forums/index.php
I did the whole B-code rear/V(?)-code front spring swap and ran 34ish tires. If you plan to load it up fairly heavy and/or tow, I think that's a great route. For me, it was a little stiffer-riding than I liked mostly because mine was fairly light for an Ex, and the V8 was miserable to tow with. The coil swap was very tempting, and would have probably happened had I kept the truck. The newer SD trucks have longer rear leaf springs also, which are another common-ish conversion in the name of plushness - I know
@broncomitch did this, but IIRC, he wasn't super impressed. Height-wise, I'd think you need very little lift (like leveling kit high only) to squeeze 35s under there, so maybe you need to run a 3" lift and 37s. Yes, you need 37s, because that truck is huge, and 37s are awesome. Trim a little and keep it low on big tires. Geared properly, your drivetrain won't even blink an eye at 37s, especially if you do go with the newer, beefier front axle.
One thing that a lot of Ex owners seem to preach is that you need to run fairly large diameter wheels if you're running larger tires, otherwise things can get wiggly in the handling department due to sidewall flex paired with the vehicles (excessive?) weight. "They" seem to prefer a 20" wheel on any tire bigger than a 35. I hate big wheels, but I do see the logic in their argument. 20s are easy to find as OEM takeoffs these days, and tire choices are plentiful. Plus, when you decide that you'll be running 37s (you will
) there is still plenty of sidewall on a 37/20 combo to be viable offroad.
I have pieces to build a stout light bar for the front that bolts to the OEM tow loop mounts if you're interested. Finished product would look very much like this:
https://www.randyellisdesign.com/store/p120/Ford_F250/F350_Super_Duty_Light_Bar_(1999-2007).html
I think I like your complete winch bumper idea more though.
The rear cargo doors are made of some sort of plastic (fiber reinforced maybe?), so be careful mounting any sort of latch/cantilever/anything to them. They're fantastically light and stout as designed, but I don't know that they'd take kindly to being incorporated into the bumper swing system. Although, I do think that is a great and convenient idea if you can pull it off.
I
may have a cargo solution for you also... I haven't decided 100% if a set of drawers that I have will work for me yet. They're made for a big Suburban/Excursion size rig, so I'd have to modify and shorten them to work for me in my Cruisers. If you are truly interested in a simple, modular drawer setup, let's talk.
I'm super excited to watch what happens with this (with 37s!)!