Kiki 06 Ford E-350, 6.0 Diesel, Van Conversion

[kikisadventures]

The hightop screwed from the outside through this aluminum profile. Then a rubber seal grabbed onto the profile.

I used a ratchet strap to full seat the hightop onto the roof.

I put a bead of silicone on the outer edge and the inner

All in all it turned out pretty good

[kbeefy]

Don't hit your head on those roof supports! 2x4 square tubing?

[kikisadventures]

I decided to patch the rear hole instead of installing the taller doors. It would have been too much work and I wasnt even convinced I wanted the taller doors

I backed the outside and fiberglassed from the inside. Then did a layer from the outside and then bondo. Turned out a lot better than i was expecting

Then I got the fan installed on this roof

[kikisadventures]

I forgot to take pics of how i did my bed frame but it's attached to the wall on one side via rivnuts and the floor on the other side. I just reused some old ikea bed slats I had lying around. I ended up needing the frame to go down the center as well after I broke some of the slats haha

The long term goal is to mount this seat under the bed. It folds down when we arent using it and when we want to have passengers, the bed frame slides back and someone can sit in the bench

[kikisadventures]

Swapped in pop out windows I picked up at a pick and pull

[kikisadventures]

I built the electronics. I plan to do solar so I made a spot but didnt install it. I more or less followed these guys but with different components (https://faroutride.com/electrical-system/). I wanted to build it on an independent chassis so I could build it outside the van and pull it to work on if I ever needed.

Inverter/Charger: Victron Multiplus Compact 12/2000/80
DC/DC Charger: Victron Orion 30 amp
Battery Bank: 4PCS Lifepo4 Rechargeable 3.2V 280Ah li-ion Lithium Battery for Solar System for EV (from alibaba)
Battery monitor: Victron BMV-712
BMS: https://overkillsolar.com/product/4s...epo4-threaded/

Once I get an AC then I'll need solar but I have more than enough power to do the little things for around 4 days with no charge. I've never plugged it in, I usually just drive to charge which has been working out fine.

My only regret is the battery monitor. I bought it before i knew I needed a BMS. The BMS has it's own app that has tons of information. I geek out on all the numbers. the monitor works fine I guess but it's just unnecessary. The BMS is great though and I would highly recommend. Same with the batteries. I was a little scared getting something from alibaba but they have been great so far.

[SteelheadJones]

I have a similar hightop. Where did you get the aluminum channel and rubber cover for it in post #31?

[kikisadventures]

Originally Posted by kbeefy

Don't hit your head on those roof supports! 2x4 square tubing?

The beams are above the bed and above the front seats so I'm not trying to stand under them. I'm 6' 2" and I have to slouch about 1" to not hit my head on the roof as is.

Originally Posted by SteelheadJones

I have a similar hightop. Where did you get the aluminum channel and rubber cover for it in post #31?

The aluminum i was able to reuse off of the donor van but I got the cover from here: https://www.recpro.com/1-white-flexi...ding-with-leg/ they might have the aluminum too

[kikisadventures]

I installed a 12V Novakool R5810 fridge. I really love it. It's huge but doesnt draw too much power

Here is a pick of the BMS app

And I pulled a sliding door with a pop out window to install later. It was really difficult to do by myself

[kikisadventures]

I made a thread here about this but I was having an issue where my boost was dumping when i got up over 7 psi. I did boost leak checks, exhaust leak checks, cleaned my turbo, replaced my turbo. I couldn't for the life of me figure out what the issue was. As a last ditch effort I decided to check if it was my EGR. I guess the EGR acts as a wastegate if there is over pressure. When I unplugged the sensor, the problem went away. I pulled the sensor (which i had replaced about a year ago) and it was dirty but not suspicious. I cleaned it and that fixed my problem. Super annoying and I could find anyone else that has had this issue. I'm glad that issue is resolved. I wasted so much time and money figuring it out.