Finished Build and Test Trip

From the previous post, we had the flooring, walls, bed, and fantastic fan put into the van. A clean pallet for building our design. If I still had Bailey’s original “inside van sketch” I would certainly post a picture of it but when we were done, it came out really close to what we were shooting for. So…. after the bed was built we moved onto the countertop, cabinet, and storage area. It was perfect for the far side of the van because there are no windows on that side of the van. It made sense. Basically, we built a storage cabinet from the floor to the ceiling directly behind the drivers seat. The lower area of that cabinet would house all of the solar system items (batteries, inverter, fuse box, etc.) and the upper shelves would be mostly food storage and whatnot. Water jugs will be housed underneath the countertop area. We built the storage cabinet and the under-counter storage to fit some cool shutters that we scored from a local friend here in town. Shoutout to Mike O’Neill! They are old antique mini shutters. The shutters are perfect for the job because they hide all of our crap while also making it easily accessible. We painted them a cream white color to match the ceiling. Bailey did a stellar job at putting some fabric that we got from Jo Ann’s on the ceiling. The trick? A whole bunch of 3M 90 spray adhesive. That shit really holds stuff good! I’ve blabbed on a lot here, but we are somewhat close to being done with the build. I’m sure I have forgotten some things. There are plenty of small things still to do and I’m sure we’ll find another hundred things to do once we hit the road, but in the mean time… we are pretty proud of our progress!

First picture above is on/off switch to turn the solar panels off to stop charging the batteries when we aren’t using them. You can also see the charge controller and fuse block. A separate write-up on the solar system is coming whenever I quit being lazy. So you’re not chomping at the bit, it’s 2 – 100 watt panels on the roof running to 2 AGM sealed Vmax batteries wired in parallel for double the storage. This is plenty of power for what we will be running (LED lights, fantastic fan, charging phones, etc).  The middle picture is the counter and cabinet just after we put the shutters on. You can see how great of a job we did. Hey, they hold stuff in!

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Installing a Fantastic Fan in our Van

After we had the flooring and walls up, it was high time we installed our new Fantastic Fan. They have many different models but after researching we decided to go with the medium model that has 3 different speed settings and the manual vent open and close. The more expensive ones that come with automatic rain sensors, reverse, 10 speeds, etc. just seemed like a little much for our application. Here is how we installed our fantastic fan vent into our 1985 Ford 4×4 van. A classic write up with lots of pictures is always good and relatively easy to follow along.

For this application, there was already a standard 14′ x 14′ hole cut that was housing an old manual vent that the previous owner installed in the van. From my research that is the scariest and/or toughest part, basically because you are cutting a hole in the roof of your rig. If you are installing the fan in an RV, there is a good chance that you already have the hole cut and are just replacing your old vent for the new Fantastic fan. This write-up is perfect for you.

To start, I needed to get onto the roof and start scraping away at the old sealant from the current vent. With a paint scraper, screwdriver (for scraping), and my drill with the proper bit, I was able to easily remove the old screws fairly easily. After the screws were out I was able to remove the old vent without much problem with a bit of Bailey’s help down below.

hole in van roof

The hole in the roof after the old vent was removed

In the photo above you can see what the hole looks like with no vent in it. Getting the vent out was pretty painless. Now the real work starts…. I’d say I spent a good hour scrubbing and scraping at all of the old sealant and caulk on the roof. Honestly this was the hardest part of the whole installation, LOL. In addition to the paint scraper and my screw driver, a bottle of mineral spirits and a rag is great in this situation. The mineral spirits really helped to bring all that old crap up without jacking up the paint. Goo gone also works just the same.

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4×4 Ford Van Flooring, Walls, and Bed

Well this is typical, it’s been almost 1 month since I last posted an update on the van. I’m gonna label the title May anyways. When you really get wrapped up in building you get kinda lazy at night and skip posting extensive updates. We have been posting little snaps here and there on our Instagram – be sure to follow us there @avantostandby. We spent the better part of the month of May building out the interior of the van and preparing it for our trip. Since our last update, we did get the radiator issue fixed. A new beefier radiator was installed along with a separate transmission cooler to eliminate the possibility of the two fluids mixing together should the radiator fail for whatever reason. That being said – the transmission and motor were also both completely flushed to ensure there was no extra tranny fluid floating around – that would not be good. So a big check – mechanical work is DONE! The van is running great all around. Now it’s time to make it livable…

bailey doing the floor

Bailey the morning of insulating and installing the flooring.

Here is how we put floors into our 1985 Ford 4×4 van. So we kind of tackled everything in sections. We started with the floors since it seemed the easiest (and because we were given some free laminate flooring, thanks Mike). We put reflectix down first with 3M adhesive spray. We used that stuff for a lot of things on this project. After the reflectix, a layer of particle board subflooring was screwed down with self driving metal screws. Finally, we installed the tongue and groove subflooring, piece by piece. A bit of liquid nail and some different heavy objects were put down on top of the flooring to ensure it was set in nice and tight. The floors came out really well. Click the below images to enlarge.

 

Next we headed to a friends house who was going to help us with the walls. We were able to get the walls and bed put in that day, a huge success. Harlan is somewhat of a professional woodworker with a lot of knowledge, and a killer set of tools. Awesome barn too! We spent Memorial Day building Continue reading