2003 Ford 7.3 PSD 15 passenger build update

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I also cut in under floor storage bought from the vendor section of the forums.

I should also mention that I made access hole in the plywood for the body to frame bushing bolts should I ever need to replace one. I also left cutouts in the plywood behind where the kitchen will go so I could make holes in the metal easily.

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I don't have a ton of pictures from the upper build. You can see that I attached wood strips to create flat sections to screw walls and cabinets too.

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I then cut in all the windows. 1 port hole on each site towards the rear. A rear sliding window to provide fresh air to the upper bunk, and another larger slider on the passenger side. All were purchased on e-bay

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then came all the panels, using 1/8" eucaboard and light gray trunk liner

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a few more of the upper area

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before I could do the lower part of the interior I had some steel windows made and powder coated, also cut in the 6 gallon suburban water heater

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now for cabinets. harbor freight to the rescue. plunge router, guide bushing, spiral bit (home depot), and hand made corner jigs/templates. I made the corners so I could attach different length sides for different opening sizes. I used this setup for every cabinet drawer or door. These are flush mount like another build I saw on here where they used a laser to cut the panels.

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formica with contact cement, trim bit with harbor freight router table, the power of the internet and two weeks later I have cabinets!

EDIT: I used black t-molding on all the edges and the insides of cabinets and drawers are covered in the gray trunk liner. there is no wood showing anywhere in the build even with the cabinets and drawers open

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more cabinets

[BroncoHauler]

So, if you're like 86Scotty (Eric), now is about the time you post your van for sale?


BTW, great work.


Herb