99 EB-50 Rebuild in Palm Springs CA

[jamlip]

Hi all. I'm starting this thread to document the interior rebuild of my 1999 7.3 4x4 EB-50 Sportsmobile.



I bought this van near Sacramento in July last year from the second owner. They had purchased it during Covid before realizing it was a bit too much for their needs. During that time, they had a local outfitter modernize the on-board electrical system and fit 12v AC, and another shop make changes to the front suspension.

I immediately took the van on a family trip to Northern California's Lost Coast. The electric systems functioned well, but the suspension work turned out to be outright dangerous.



Once home, I replaced the shocks and springs with the combo used in the ride-improvement kits regularly mentioned on this board. Shortly after I also removed the front sway bar. The van now rides beautifully both on and off road.



Other changes since then include replacing SMB's 90s-style billet grille with a factory unit from an E350 work truck (which also had the benefit of greatly improving the output of the AC), reinstating the winch, fitting LED headlamps and backup lights, removing the Fiama awning (which was buckling the sheet metal around the clamps as a result of driving off-road), fitting Bushwacker fender flares, and installing a Sony double-DIN stereo with backup camera.

In the last 12 months I've taken the van up to Walla Walla WA, the last ever Reno Air Races, skiing in Grand Targhee ID and fishing along the Colorado River around Yuma AZ. My wife, son and I moved to the US from the UK in 2017 and quickly discovered we loved to camp (camping in Britain absolutely sucks, for the record). I am pretty sure a Sportsmobile is one of the best ways to experience the wild corners of amazing country.



At the end of last month I took the van to Burning Man and was delighted to return home safely with only a broken rear spring hanger. I cleaned out the fridge and gray water tank, vacuumed-out all the dust, and put the van back into my hangar where it lives, figuring I would get to the broken spring hanger the weekend after.

Some time during the week, the portable toilet, which I had forgotten to empty, exploded, emptying a putrid mess into the interior. I won't go into any more details here, but if you want to read about this sorry situation, this is the thread

With the van now coming up on 25 years old, I was aware an interior refit would some day be required. This event brought the decision forward somewhat.

And so begins my rebuild thread...

[jamlip]

I have already started to gut the interior. I like the EB-50 layout and plan to rebuilding the cabinetry in birch or poplar ply.

I plan to reuse the existing propane heater, and fit a new gas cooktop and new 12v fridge.

The van is currently fitted with a massive AIMS Global 3000w inverter and a microwave, neither of which we really need. I've removed both and will sell the inverter. I'm going to use that leftover space for more water storage.

I currently have two 300Ah batteries on board, charged via a Renogy controller. I'll fit a smaller Victron 800w inverter for running laptops and suchlike.

I would like to add mass loaded vinyl (FatMat or similar) to the cab area to help control engine noise from the mighty 7.3. I am not going to sound-insulate the back of the van since we actively seek-out quiet camp spots.

I do need to work out rear thermal insulation options. The insulation situation at present is pitiful.

I'm going to add a new carpet to the cab. I have ordered boat flooring samples for the rear. I need to investigate other fabrics for the wall panels and seats.

[Twoxentrix]

Well you are waisting any time! Many here will be ‘fans in the stands’ as you progress, but available for suggestions & ideas (as you’ve already discovered).

[1der]

Yes, nice to see you getting started!

Some ideas -
Remove the HUGE propane heater and replace with a diesel fired heater the size of a loaf of bread and MUCH nicer and quieter heat.

A 1600w to 2000w range inverter will allow use of power tools, microwave, etc. 800w is pretty smalll.

600 ah of Lithium ?? What is this for if only charging laptops and ??

Water tank/ capacity - consider two tanks to better utilize space while increasing capacity versus one large tank. Incorporate a larger O ring sealed 3" diameter port for filling from jugs or a hose versus having to fill thru the city water port or a funnel under the seat.

RAISE the counter height !!

[jamlip]

Thanks for the ideas guys.

When I started the tear-down I realized my biggest hurdle was going to be indecision on how to equip the van.

The biggest draw on the cells is the no-brand "Kingtec" 12V rooftop air conditioner. It's not very good, but it does take a slight edge off the heat here in the desert. I'd like to change it out for a 12v Dometic unit down the line.

600Ah doesn't leave much AC once you've run the microwave for five minutes. I've never used the outlets for anything except a laptop charger and most of my power tools are cordless anyway.

Regarding the heater - better-the-devil-you-know etc. I already have propane on board, I know it works at all altitudes, and keeping it saves $1500. Only downside I can see is space. But it's also easy to change my mind later, if required.

Deck plate on the tank is a GREAT idea, thank you.

[1der]

How are you charging the lith battery bank ?
You mentioned Renogy Controller but what "Renogy"?

[jamlip]

Renogy charge controller fed with alternator and solar

[1der]

Originally Posted by jamlip

Renogy charge controller fed with alternator and solar

I think that maxes out at 50A. So, maybe 40A to 45A getting to the batteries. That means the recharge of the lithium bank takes a while.
What do you have for alternator(s)?

[jamlip]

Single factory alternator (unsure of amperage).

Looks new-ish, perhaps all that work was stressing it out.

Unrelated - I keep finding the word "FEB50 Demo" written on the back of trim pieces as I remove them. Perhaps it was a demonstrator.

[Twoxentrix]

I’ll throw in a word of caution concerning the location of any equipment you install (re-install) which have lights integrated into them (battery monitors, solar control plates, CO detectors, etc).. position them so when you retire in the evening they do not shine towards your head - gets to be real annoying having to contend with that glow at night.
Also, since everything is apart, run some extra wires around the inside so down the road if you intend to ‘add’ anything extra you don’t spend time navigating them around all your cabinets and appliances.