Author Topic: Summer van project (Read 24327 times)

Testarossa · « **on:** April 04, 2015, 10:03:59 PM »

Gail and I have begun looking for a used AWD cargo van. I'm hoping we can find a rust-free example with around 75,000 miles in the $15k range.

Goal is to build our own on-the-cheap version of a Sportsmobile. I want to install a high top with thermal windows, insulate the floor, sides and top, run wiring, install tanks and plumbing INSIDE the insulated envelope, install paneling and build cabinetry with the usual RV appliances -- and have it ready to go skiing next winter. I've done my own home renovations including the complete finish carpentry of a geodesic dome, and a van is obviously a much smaller project.

Has anyone in this group done a similar conversion? Looking for advice and ideas.

I'd buy something ready to go but the prices with AWD and decent insulation are astronomical -- $45,000 for a Sportsmobile diesel with 200,000 miles and some undercarriage rust? I think I can build my own rig for half that.

Antietam Classic Cycle · « **Reply #1 on:** April 04, 2015, 10:18:16 PM »

A heat source to consider: http://westyventures.com/propex.html (Westy Ventures/Propex US is my brother Karl).

cruzziguzzi · « **Reply #2 on:** April 04, 2015, 10:23:42 PM »

What's the start-up budget?

Probably gonna be expensive any way you go.

3/4 ton is minimum but I'd skip past that and go 1 ton if not 5/4 or better. Better brakes, bearings, springs, etc...

The front axle is never gonna be a cheap go on these regardless of the state of the vehicle.

For interior bits - though it's distant for you - I've had great luck for boats (consider these as sources of equipment and ideas), campers and RVs I love prowling Quartzite, Arizona during the "season" for components. There're a butt-load of take-offs there in the winter. RVs and campers come from all over the continent to die there.

Base vehicles... I'd watch the auctions for former utility/rail road/forestry vans. WSM has been very good to me and over the years I've seen a couple three FWD vans go through. Beware the Dodges for having 1/2 ton front ends on a "3/4 ton" chassis.

To watch, if only for comps:

http://wsmauctioneers.com/

https://www.rbauction.com/

http://auctionaz.com/

BillinPA · « **Reply #3 on:** April 05, 2015, 06:18:47 AM »

There are several builds like this on ADVrider. Some are very detailed. Could be some good info there. Sounds like a fun project.

EldoMike · « **Reply #4 on:** April 05, 2015, 07:22:15 AM »

Lot of good stuff here....

http://expeditionportal.com/

charlie b · « **Reply #5 on:** April 05, 2015, 07:45:27 AM »

Have you had an RV before? Do you know what you want inside and what you don't?

It all depends a lot on where you will be parking and what you need inside.

If staying at a full service campground all you need are beds and storage space. Put swivel seats in front so you can use them for relaxing. Heater can be built in or use a portable. If it were me I'd add a portapotti since I hate going out in the middle of the night (especially when it is cold out). My experience is that storage space is the biggest item.

Electrical. For simple when shore power is available is to just have a few outlets wired in.

LowRyter · « **Reply #6 on:** April 05, 2015, 08:58:04 AM »

Good luck with your quest. I got the bug to get a small box trailer to pull with my V6 Isuzu Tooper to camp and haul a motorcycle. Then I wanted a bed, kitchen, air, etc. Anyway, by the time I was done, I ended up with this (no 4wd either):

Testarossa · « **Reply #7 on:** April 05, 2015, 09:19:10 AM »

Yes, I've had an RV -- this monster 1977 Ford Econoline that got 7mpg. I got rid of it last year.

Thanks for all the great feedback and especially the source links.

We plan to travel year-round but the critical use will be in ski resort parking lots, which means January storms at 8,000 feet elevation. I want self-contained, fully independent living -- we need to keep warm on propane, hence the full insulation and interior tanks.

Floorplan I envision now is:

Swivelling seats in front with storage cabinet over, double bed in back with tanks and storage under, storage over
Driver's side, front to back: toilet/shower with ski rack inside; fridge/microwave; pantry; locker
Passenger side: folding table; sink/stovetop with water heater; folding worktable
300-watt solar system on top

Testarossa · « **Reply #8 on:** April 24, 2015, 10:53:30 AM »

Gail and I went van shopping yesterday and found our vehicle: a 2007 Chevy Express XT cargo van with AWD. It's high mileage but rust free and very clean with good compression on a remanufactured engine, and new tires. We'll pick it up next week after it gets a new transfer case.

We plan to put in the first layer of insulation just to quiet the ride, then throw in our camping gear and bicycles for a shake-down cruise out to the West Coast. Might carry the Triumph for this trip and have some fun on the Coast Highway for a couple of days.

When we get home, will install the high top, complete the insulation, install the tanks and begin work on cabinetry. Hope to have a winter-capable machine by November.

Anyone here worked with polyiso foam board insulation? It appears to offer the best R-value per thickness/weight --

Lannis · « **Reply #9 on:** April 24, 2015, 11:01:32 AM »

Quote from: Testarossa on April 24, 2015, 10:53:30 AM

Gail and I went van shopping yesterday and found our vehicle: a 2007 Chevy Express XT cargo van with AWD. It's high mileage but rust free and very clean with good compression on a remanufactured engine, and new tires. We'll pick it up next week after it gets a new transfer case.

We plan to put in the first layer of insulation just to quiet the ride, then throw in our camping gear and bicycles for a shake-down cruise out to the West Coast. Might carry the Triumph for this trip and have some fun on the Coast Highway for a couple of days.

When we get home, will install the high top, complete the insulation, install the tanks and begin work on cabinetry. Hope to have a winter-capable machine by November.

Anyone here worked with polyiso foam board insulation? It appears to offer the best R-value per thickness/weight --

As I found as I was building my house, there are people that can do things like install insulation and conversion van tops for a price you almost can't refuse.

For example, I was building my house in the '90s, I had a contractor account at the big local building supply place for cheap materials. I had finished the wiring and plumbing and was ready to insulate (3 stories, 1000 sq feet each, 10' ceilings, walls only). I priced all the insulation batts at $1200, and went down to place the order. The salesman gave me a nod and a wink and said "Call this guy". "This guy" (who was one of their customers) quoted supplying AND INSTALLING all the insulation for $900, and finished it in a day.

I'd have been covered in fiberglass bits and itching and sweating for a week ....

Lannis

RinkRat II · « **Reply #10 on:** April 24, 2015, 11:31:30 AM »

Cool Project! You might consider closed cell foam sprayed in insulation after your preliminary layout and foundations. Also a handy thing is to lay out pvc pipe for all your electrical and plumbing runs as you can insulate right over it all. :pop

Paul :BEER:

rodekyll · « **Reply #11 on:** April 24, 2015, 11:48:10 AM »

Have you thought about repurposing a medic unit?

Testarossa · « **Reply #12 on:** April 24, 2015, 12:19:15 PM »

Lannis, that's great advice!

Rodekyll, I looked at some ambulances and decided it's more trouble than it's worth to rip out and modify the heavy-duty built-in cabinetry. Much easier to start from scratch and build exactly what we want.

For the same reason I passed on a very interesting truck that was well insulated and air-conditioned -- and divided into small prisoner-transport cells with heavy steel walls welded (not bolted) into place.

Besides -- our first decision in this process was to buy locally and not purchase anything sight unseen from people we hadn't met face to face.

I learned early on that when Gail is present, sellers are friendlier and more flexible on price . . .

Testarossa · « **Reply #13 on:** May 03, 2015, 10:10:52 PM »

We bought the van. High miles but very clean and nothing drips or oozes. I drove it up to ABasin and back yesterday and got 17.5 mpg -- might do better on the flat.

Over 60mph it's loud inside, like living in a bass drum. First step is to install some serious insulation just to control the loud. Then a mattress, cook stove and water tank, and we're off to California May 17.

Testarossa · « **Reply #14 on:** May 06, 2015, 06:45:51 PM »

Began insulating the van. When I pulled up the nice clean rubber mat in the cargo bed, we found the underlying insulating mat -- apparently made from recycled carpet fiber -- was soaked. I'll bet someone at the previous dealer hosed the interior. It all came out and I spent a couple of hours cleaning up the floor with a wire brush and primer. Used silicone caulk and plastic plugs to seal the bolt holes in the floor.

When it was all dry, I put down two inches of polyiso foam board, with foil on both sides. The stuff cuts easily with a bread knife. Half-inch strand board over the insulation, which will be a bed for a cork or laminated floor. Put Reflectix on the walls and doors -- the walls will get polyiso board after the high top goes on.

nick949 · « **Reply #15 on:** May 06, 2015, 07:23:04 PM »

Good luck with your project ;-T I have a 2004 Savanna AWD which I really like about 50% of the time. It's been reliable, drives really well, is truly terrific in the snow and I have taken it down some muddy 4-wheeler trails that any sane person would fear to go without getting stuck (ripped the rear heater hose on a stump, but that's another story). It even gets half-decent fuel mileage.......But.. ...

I just wish the rest of it was acceptable. The build quality is atrocious. None of the body panels fit properly, it's rust prone, the metal is paper thin and body panels easily get bent etc. etc. The plastic parts are rubbish and the hinges on the side doors are beneath contempt and have snapped (keep those well lubricated - it's a well known issue, never dealt with by GM). Whoever designed and assembled this box deserves........... .well, my disdain is probably apparent. Perhaps if GM had done the powertrain then let the Koreans handle the body work, it would have been a far better vehicle.

Damn that sounds grumpy! It's a good job I like my bikes.

Nick

Testarossa · « **Reply #16 on:** May 07, 2015, 09:40:01 AM »

Nick, I was aware of some of the body problems. This van spent most of its life in Las Vegas and has no rust. The only sheet-metal issue is that something underneath -- a heat shield probably -- resonates at 60+ mph so loudly that you can feel the vibration up through the seats. I'll be under the van this morning looking for the source. Any ideas would be welcome.

nick949 · « **Reply #17 on:** May 07, 2015, 10:32:29 AM »

Quote from: Testarossa on May 07, 2015, 09:40:01 AM

Nick, I was aware of some of the body problems. This van spent most of its life in Las Vegas and has no rust. The only sheet-metal issue is that something underneath -- a heat shield probably -- resonates at 60+ mph so loudly that you can feel the vibration up through the seats. I'll be under the van this morning looking for the source. Any ideas would be welcome.

You're lucky to live in the sun belt ;-T My van is ex-Canadian Forces so was fleet maintained and mechanically very sound. Unfortunately I think it spent its early life somewhere near the sea because rust has certainly got a hold and our winter salt doesn't help.

Perhaps your muffler is drumming against the body. In the winter, ice will build up between the body and the exhaust pipe and will make a horrid din until the heat of the pipe melts a little space. Perhaps one of your muffler hangers is letting the pipe bang around.

The only mechanical issue I have had is with front wheel bearings. Both were replaced before 100,000 miles. They will give you plenty of warning, with nasty screeching and clunking sounds. Fortunately they are relatively cheap to replace.

I bought mine for the AWD - and it has exceeded my expectations. It's a great system that really works.

Good luck.

Nick

Testarossa · « **Reply #18 on:** May 12, 2015, 01:21:38 PM »

Drumming turned out to be a bad bearing in the transfer case -- a part the dealer replaced, so it's under warranty. Should be back on the road by Thursday. Meanwhile, Gail photoshopped this art -- it's the trucking company my grandfather started in 1918.

Testarossa · « **Reply #19 on:** May 14, 2015, 06:05:43 PM »

Progress!
http://skiyoungernow.com/gail-and-seth-hit-the-road

nick949 · « **Reply #20 on:** May 14, 2015, 06:31:40 PM »

Nice write up Seth- Have fun.

Nick

Ps My friend F*&^&ing Doug has my van for a couple of days to do some body work. Your work is inspirational.

Testarossa · « **Reply #21 on:** June 02, 2015, 11:41:50 AM »

We're back from the van's shakedown cruise. 3900 miles, 17.7 mpg, 2 quarts of oil and an exhaust leak repair. Had a great time!

http://skiyoungernow.com/gail-and-seth-hit-the-road/

Lunching in luxury at Big Sur:

Lannis · « **Reply #22 on:** June 03, 2015, 11:09:29 AM »

Quote from: Testarossa on June 02, 2015, 11:41:50 AM

We're back from the van's shakedown cruise. 3900 miles, 17.7 mpg, 2 quarts of oil and an exhaust leak repair. Had a great time!

http://skiyoungernow.com/gail-and-seth-hit-the-road/

Lunching in luxury at Big Sur:

Looks like the trip was a lot of fun and the van's working out well!

You need to go ahead and put the "Masia Brothers'" sign on there for real, that's sort of neat. Or maybe have some artist recreate their original logo that went on the chain-drive Mack Bulldog equipment they originally used!

And given what's all inside, maybe an old "If this van's rockin', don't come knockin'" sign like the hippie VWs used to have ... !!

Lannis

Testarossa · « **Reply #23 on:** June 03, 2015, 03:29:03 PM »

Lannis, the issue of art for the outside of the van is a continuing discussion. Gail is a graphic designer, and my daughter has a fresh MFA, so I've left that topic for that committee of two.

We rode the T up to Fort Collins today to lunch with the daughter, and en route stopped at Colorado Camper Van in Loveland to order our Fiberine 24-inch high top. Should have it installed just after we get back from the Cripple Creek NAR.

Testarossa · « **Reply #24 on:** July 19, 2015, 03:55:28 PM »

Well, we hit a road block with the high top installation.

On June 3 I put down $1500 with a local shop to order and install the top, and they ordered it from Fiberine in Long Beach. Delivery expected in three to four weeks, installation to take one day. On June 26 I phoned and emailed to learn the status, and got no reply. I've now learned that on June 6, Fiberine asked the local guy to confirm the order. He didn't get back to them until July 1.

Now Fiberine has built the top and crated it, and they say they're waiting for payment from my local guy; he doesn't return their calls, nor mine. But his wife says they always pay when the top ships.

So now I think I'll buy it directly from Fiberine, claw my $1500 back from Visa -- and install it myself. I think I can have it here by Friday, which will be July 24.

Meanwhile I've installed the receiver and a carrier to take up to a 600-lb bike.

Testarossa · « **Reply #25 on:** August 08, 2015, 06:57:44 PM »

We finally got the high top on, a month late. But I'm happy with the result. Now it needs a roof vent and insulation, then we'll build the cabinets.

The Triumph just wasn't quite right. After a great Fathers Day ride it became hard to start -- so I ran it down to Vintage Twins where Dave breathed on it. He replaced the o-ring seal between the carb and manifold with a real gasket, curing the sporadic air leak there. He reset the timing -- I had the Boyer system set up like the points, and he moved the static mark up 20 degrees. Now it's back to second-kick start and pulls strong at all speeds. I'm very happy and now I want to keep it. When this bike acts up, I want to sell it; when it runs right I'm in love. Having seen how Dave sets it up, I'm sure I can keep it running well for as long as I care to ride . . .

Meanwhile I took the ugly black top-box off the T and engineered a removable backrest for Gail, bolted to the tail rack. Looks much cleaner, feels less tail-waggy, and Gail is happy. So for now the T is the touring rig and the Triumph is my around-town ride.

Testarossa · « **Reply #26 on:** August 15, 2015, 06:28:59 PM »

Installed the roof vent, with its electric exhaust fan. It’s a lot more comfortable working inside now, and we’re making good progress finishing the insulation.

Next: panelling and wiring, then the kitchen cabinet with sink, water tanks and cook top. We have the 12-volt refrigerator ready to strap in, and the 220 amp-hour battery set, so we're ready for the next trip. The photovoltaic panels and 1000-watt inverter can wait until we return.

flip · « **Reply #27 on:** August 15, 2015, 07:16:58 PM »

Nice rig!

What make/model motorcycle carrier did you go with?

Red07 · « **Reply #28 on:** August 15, 2015, 07:51:19 PM »

Nice project. It'll be great when you get it all finished.

"She's gonna love me in my Chevy van and that's all right with me"

Randy

Testarossa · « **Reply #29 on:** August 15, 2015, 10:32:28 PM »

Flip, I got a cheap steel carrier from Discount Ramps. 600 lb rating. This one:
http://www.discountramps.com/hitch-mounted-steel-motorcycle-carrier/p/MCC-600/

It weighs about 90 lb and so is kind of a pain to wrestle it around in the garage.

News:

Author Topic: Summer van project (Read 24327 times)