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149 Posts
Hi folks,
I'm somewhat new to the forum but I have been reading and developing a plan for a van conversion for the past 6 months or so and I now have the van and much of the gear needed to begin my build...
Meet Sandy (a.k.a., a 2020 136WB HT Promaster in Sandstone Pearlcoat). Apparently, the color is pretty rare, as we've never seen one in the wild and the dealer told me that it was the first one they had ever received from FCA. We bought it new and just picked it up from the dealership... in Wisconsin... (we live in California), so we made a road trip over the weekend to go get it. 2000+ miles on the trip and I've learned a few things about how it handles, etc.
It's a clean slate, and I will be making a bunch of modifications to it over the next few weeks in preparation for the actual conversion work to begin. The mods will probably go in this order:
Most of these steps have LOTS of smaller steps along the way, but on the whole, this represents a reasonable high level project breakdown.
My plan is to use 8020 for the galley andbaltic birch or similar plywood USA-sourced Maple plywood for the bed and garage portions. This is pre-finished on both sides, so that simplifies some aspects of the fabrication.
I will try to document the progress some and make updates to this thread. I'm not sure if I should ask questions in here or start another thread for any specific questions that I still have or will come across as I build.
I'm somewhat new to the forum but I have been reading and developing a plan for a van conversion for the past 6 months or so and I now have the van and much of the gear needed to begin my build...
Meet Sandy (a.k.a., a 2020 136WB HT Promaster in Sandstone Pearlcoat). Apparently, the color is pretty rare, as we've never seen one in the wild and the dealer told me that it was the first one they had ever received from FCA. We bought it new and just picked it up from the dealership... in Wisconsin... (we live in California), so we made a road trip over the weekend to go get it. 2000+ miles on the trip and I've learned a few things about how it handles, etc.
It's a clean slate, and I will be making a bunch of modifications to it over the next few weeks in preparation for the actual conversion work to begin. The mods will probably go in this order:
Swivel seats and lowered bases(so I can then make final measurements on available space for the galley, etc). COMPLETED 10/21/20Vent fanCOMPLETED 10/29/20Install CRL windows in the front L and R panelsCOMPLETED 11/7/20Install CRL windows in the rear L and R panelsCOMPLETED 11/2/20Remove black ABS paneling on insideCOMPLETED 10/30/20- Insulation for walls and roof (
Remove all the ABS panels-Noico- Thinsulate)
Sumo springs for front and rearREAR COMPLETED 10/22/20 FRONT COMPLETED 10/23/20Solar panels on roof (Went with an 8020 frame and DIYVan mounts. Waiting for final parts to put on roof.)COMPLETED 12/7/20Install Dragonfly tarp railCOMPLETED 11/29/20Upgraded stereo and/or speakers (Kenwood Head unit, and Hertz speakers)SPEAKERS INSTALLED 12/6/20 HEAD UNIT INSTALLED 12/13/20AT tiresFALKEN AT3W INSTALLED 1/26/21External step (Thule)COMPLETED 1/24/21- Espar B4 heater (Need to determine location first)
Install NOCO 15-amp plugCOMPLETED 10/23/20Install rearview camera wiring and cameraREAR CAMERA INSTALLED 11/29/20 WIRING INSTALLED AND BEHIND HEADLINER 12/22/20Install Class III trailer hitchCOMPLETED 12/21/20
- Floor install
- Cut
foam,subfloor,floorFOAM AND SUBFLOOR CUT AND TEMPORARILY INSTALLED 11/20/2 Figure out reinforcement locations (under galley, at doors, at L-track points)COMPLETED 12/14/20Fabricate floor sills at side and read door.COMPLETED 1/9/21Fabricate final subfloorCOMPLETED 1/17/21Determine whether biscuit joints or a lapped joint on the main floor will work best. Fabricate main floor joints.DECIDED ON LAPPED JOINTS. COMPLETED 1/23/21Do final insert of flooring and finish floor before furniture installCOMPLETED 1/24/21- Insert floor L-track points and secure floor in final position
- Preliminary electrical
Rough electrical design and sizingCOMPLETED 1/10/21- Layout electrical on breadboard with components
- Figure out the 3D layout for install in van available space
- Do final wiring in actual van space
Install solar wiringCOMPLETED 12/7/20- Install alt. battery wire
- Install controller for Thule Powerstep
- Install hookup for AC power to inverter/charger
- Install DCC50S
- Install Xantrex 2000 XC
- Install batteries (2 Lion Energy UC1300)
- Install fuses and bus bars
- Install disconnects
- Install load centers
- Install wiring between devices
- Do final safety tests and confirm wiring and connection integrity
- Finish cabinetry around electrical
- Bed and garage upfit
- Make rough layout and test connection methods
- Fabricate bed area
- Fabricate sliding cabinets
- Assemble and test
- Galley
Galley carcass constructionCOMPLETED 11/30/20Galley drawers construction and installationCOMPLETED 1/25/21- Galley countertop fabrication
- Sink install
- Plumbing for sink and drain
- Electrical for pump
- Door/drawer front fabrication and install
- Upper cabinets construction
- Place 8020 connection points on van
- Place remaining 8020 and get door and reinforcing positioned
- Fabricate sides and door fronts for cabinets
- Final install of doors and sides/bases
- Wall and ceiling finish
- Make wall panel forms for the fabric sections
- Make patterns for metal ceiling sections
- Make window surround forms for all windows
- Wrap wall panels with foam and fabric
- Install fabric segments
- Install metal segments
- Install L-track on ceiling and pieces on rear pillars and doors
- Final electrical
- Install switches
- Install outlets 120v
- Install outlets 12v
- Install monitoring panels
- Install lights
- Connect pump
- Connect refrigerator
- Connect smoke and CO detector
- Final Elements
- Order cushions
- Install Lagon table
- Install fire extinguisher
- Purchase champagne
Most of these steps have LOTS of smaller steps along the way, but on the whole, this represents a reasonable high level project breakdown.
My plan is to use 8020 for the galley and
I will try to document the progress some and make updates to this thread. I'm not sure if I should ask questions in here or start another thread for any specific questions that I still have or will come across as I build.