[pvangel]

Well I bought a 2014 136" high roof back when there was snow on the ground and just completed it recently.

58,000 miles and in great shape.


I wasn't planning on getting a crew cab with divider but turned out to work well for what I wanted which is to be able to carry 2-3 dirt bikes for weekend events with my son and I.


I started with a MaxAir fan, always tough cutting a hole in a perfectly good roof.

 

[pvangel]

Next was a venting window in door.

I wired up for lighting.

Added insulation and started a shiplap ceiling.

And fired out the walls.

 

[pvangel]

I ended up getting the walls spray foamed with closed cell foam, mostly because I had them spraying a house for me so the price was right....nothing

I put in blocking where I knew I would be mounting things, this would be my fold down dressing seat and step to bed.

And then plywooded the walls.

The flooring in above and below picture was a 12x12 vinyl tile that buckled so much in the heat of the sun I ended taking it out.

 

[pvangel]

I started front cabinet by making a square surface off the curved walls.

And then started the cabinet frame with 1-1/4" square tube

Put in for a test fit.

And welded it all up!

 

[pvangel]

Making it all fit

And the fold down bed.

And my dressing seat.

Had to make sure the cooler fit!

 

[pvangel]

I used the 12x12 tile as a template for the roll of diamond plate that I will glue down.

And glued it in.

I used the flooring as a wainscotting as well.

And then finished the walls with shiplap.

 

[phil]

Any buckling with the diamond plate?

Any issues with the exterior after the foaming?

 

[pvangel]

Very minor buckling on the floor, it is much better then the tiles.


The foam did create some waves in the exterior panels, these vans have some "movement" to them but I can see where the foam pulled in the panels. Nobody else has noticed it but it does bother me a bit. I have some graphics(not a wrap) coming for it that will take your eye away from it though.

 

[phil]

I suspect it's would be less noticeable on a white van.

Great postings by the way

 

[pvangel]

This is pic of side of van after it was done and none of the distortion of panels shows up, only when you look right down the side in the correct light.

 

[pvangel]

I ordered foam for bed and seat.

Cut it to size.

And had my wife make covers for them.

With matching curtains!

Back to the cabinet...

 

[pvangel]

Water tank and battery will be housed in this cabinet.

Bed folds down on top of cabinet as well as being supported by straps, fold out seat is for getting race gear on and as a step into bed.

Cabinet doors have plywood inset with the flooring material glued to it.

And countertop is floor material as well.

Grab handle for easy access is painted in red as well as the bike wheel chocks and tie down points.

 

[pvangel]

Although it seems like I did this fast it took me 3-4 months to do this working nights and weekends and I don't have a garage so all work was done in the driveway when weather permitted but it was coming along.

 

[captainrob]

Perfect build for the use it seems! I like that you tied in the flooring on other surfaces. What glue did you use for the floor?

Sent from my SM-G930T using Tapatalk

 

[pvangel]

Roberts 2057

 

[pvangel]

Mounted up the water tank and pump, battery is in but wiring is temporary.

Then I could close up the cabinet.

And test fit the bikes.

I wanted to be able to sleep in bed with bikes in there and it works!

Installed my light switches and water fill in the "dashboard"

 

[pvangel]

My accessories showed up! Helmet holders,shelves and fold out tables.

 

[MsNomer]

Another fine entry in the "Grownups Pinewood Derby"! Love your ingenuity and skill.

 

[pvangel]

Next was to button up the wiring, I in general am only gone for a night or two and have found that a deep cell battery will last for much more then that. I spent two nights in it last weekend and used the shower (pics coming of that) lights and fan off and on all weekend as well as two day rides since and the battery is still showing 12v. Having built a few of these before I have found it to keep my electrical as simple as possible.


So..... I have two 110 outlets which just come off an extension cord that I can plug my generator into or the house.

A battery tender lives in cabinet so will charge battery anytime the van is plugged in.

My shore power cord which is about as simple as it gets.

And the 12v is all buttoned up

Maxxair fan remote control mounted up, This is nice because I can take to bed to shut off while up there.

Reading light by bed is dimable and can be shut off from switch or at fixture.

 

[lsd673]

Enjoying your build process... may i know where you found your stainless accessories? Thanks ~ Steve