The time has came to strip out my shoddy work from the first build on the Polar express done quickly and in hast back in 2016. It was enough to get me camping but I’m looking forward to a real functional camper. Lived with the old setup for 5 years before deciding to do it right, so here is attempt #2 and even the third attempt on the galley .
Some background on this vehicle , the 2013 Regular body E 350 was purchased with the CCV high top with only 32 k miles. . I did the TTB Agile offroad conversion a year later and did a quick install of a cheap van couch and fabric panels throughout the interior..
I’ve got some Aluminess goodies and she’s already seen some great backcountry and snow days.
The cheapo van couch, which at the time was not cheap was a disaster from the begining, I ordered it too big and cumbersome, and used up almost all the interior space in the rear and produced the most uncomfortable bed that you could not lay flat on lengthwise.
I used the the old van rug floor I bought it with and built a squeeky first version van kitchen out of 2x4. The van rug served me well but it was time to have a real floor, since the previous owner rhino lined the whole interior already it was a good start.
I stripped al the old crap out quickly, and sold anything I could on craigslist to help fund the remodel. Surprisingly, the items went fast on craigslist, and I still have a few things including the SMEV burner sink combo, and a custom countertop that it fits into. PM me if any interest.
In any case, the build included, new insulated sub floor, new kitchen galley, all new electrical, and new fold down seat bed for the rear.
Here is the beginnings of the remodel when you thrown everything out of the van ready to go. Two weeks later it’s all still there.
Once everything was stripped out I sat and sat inside thinking about improvements and locations. And measuring each dimension over and over.
First thing is an insulated subfloor, I decided to use treated and sealed 1/2 inch birch and the standard dynamat butyl tape combined with aluminum foam insulation. The -Lynwood resting and screwed in on top with stock mounting points and a few screws.
I sprayed the underside where any screw popped out with rustoleum.
Next was a trip to LOnseal in Anaheium to pick up my floor, I asked for a grey loncoin, but afterwards realized there are so many new and better options including simulated tweed and others that would have been a much better look. My only regret on the build is my floor choice. It’s a hell of a lot better than the old van rug though
The lonseal rep said the tape works great so I used it to not have to deal with adhesives, so far so good. Floor is stuck wel to the plywood. But could be pealed up if ever needed
Next was the seat bed, a trip to a warehouse somewhere in LA and cash in hand I picked up this two seater reclining sprinter seat bed.
here it is in down position, almost a full size bed at 48’. I will be filling in the driver side rear with a custom box made from 80/20 and wood paneling and a pad on top to house the water heater and diesel heater.
17 gallon Water tank and the 300 AH lithium battery will stay under the seat and fit quite well
Here is the giant 300 AH lithium more chinese made products in the van. Seems solid and reliable so far with fridge and fan on in so cal daily heat I’m using w-volts and battery topped and fluctuates between 98-100 percent full.
Next was modifying the kitchen galley so the seat bed clears when folded down and the pull out ARB fridge is functional and easy to happen A new sink and will have two drawers made under the sink.
some electrical on the rear panel of kitchen and my giant 3000 inverter mounted on the drivers side.
Used carbonized 3/4 bamboo for the countertop and had my local cabinet shop cut and seal it. Only to cut out a large chink for the sink.
Moving on to electrical I had asked in a post about dc to dc chargers and the max output I can use with the stock alternator. the 40 amp is plenty and I have it switched so I can turn it on while underway at higher RPM's
The electrical now has Renogy 40 amp DC to DC charging, a new renogy solar controller, 3000 watt renogy inverter. 2 AWG cables to 4 and 6 awg around the van. The inverter needs the 2awg all the way as its about 10 feet away from the battery.
Next Up, is to remove rear passenger windows of which one leaks badly and replace with aluminum sheet panels. I am talking with my local sheet metal fabricator to do this. Any thoughts on if someone has the dimensions of the windows, if so let me know as it will save me some time. Ill punch in some bunk windows and finally rid myself of this glass house we camp in.
Also in the future is hot water heater and reinstallation of my diesel heater.
waiting on the water tank which is 17 gallon instead of the old ten.
So.... many needed upgrades a much more spacious interior, new kitchen, floor and bed. And now I can finally make a cup of coffee in seconds not minutes.
2008 GMC 3500 SMB
Linear Mode
