Chevy Express Project (Europe, Switzerland)

saabman · 02-27-2009, 02:56 PM

Hi All ok here we go for my project log:

1998 Chevy Express 2500 LS Passenger Van
5.7 petrol V8
2WD 4 speed auto
Seats 12 people

Here are a couple of photos of my Van (yes I grabbed them from my other post but I thought I would do a proper follow-up):

The Chevy Express:

The front:

The cockpit:

The current seating layout:

saabman · 02-27-2009, 03:04 PM

OK here we go!

Today I went to Ikea and bought 3 baby mattresses of 60cm x 120cm to create the rear double bed which gives us a 120cm x 180cm bed.

Cost 128.30 USD

Ordered the panels for the construction as well, collecting them tomorrow... or at least for us over here... not quite sure when it will be for you

saabman · 03-02-2009, 02:14 PM

Got the MDF special water resistant grade (was about half price compared to marine ply!!!)
Cost Calculations will come later.... Started building the rear compartment i.e. a double bed convertible into 2 benches and table. Not yet very clear on the pictures... but will be as things move on...

Cutting floor panel:

Preliminary installation to check fit:

Angle view:

More news soon

saabman · 03-09-2009, 02:52 AM

After having laid the rubber floor on the base panel I started by installing the table legs and then covering the table section with "sand" colored vinyl. This should suit my interior trim ok-ish the trim is a bit darker...

I used the Missus' kitchen pastry roller to remove the last bubbles from under the vinyl before the glue dried too much

luckily I didn't get it too dirty ...

jage · 03-09-2009, 08:12 AM

Ah suddenly the four vertical boards make sense!

Are you doing something more the the seat fronts to keep them from folding than what is visible in the photos?

saabman · 03-09-2009, 08:24 AM

Jage I am not sure I understand your question?

If it is to avoid the seat benches (the ones I am building) from flopping over I have more photos coming this evening (later today for you

) to show more... but I have cross panels to be fitted for rigidity...

Is that what you were wondering

jage · 03-09-2009, 08:25 AM

Yup, that's it. Every time I see those I wonder if you've got plans to brace them better.

saabman · 03-09-2009, 08:32 AM

Yes the first photos were really only trial fitting for the dimensions etc...
I will have a panel blocking off the "box sections" i.e. under the seats, this will avoid any cargo sliding forwards into the seating area. To the rear near the van's rear doors I might (not sure yet - testing needed) add a thin metal reinforcement, for the same reason but thus allowing cargo to be loaded easily from the rear...

I am posting almost "real time" so things will get more clear as we go along ... I hope