2003 Ford 7.3 PSD 15 passenger build update

[Bbasso]

Fantastic.

But just one question, why that type of water heater?

[luked]

Originally Posted by arctictraveller

Wow, really nice work. I'd love to see a couple photos of the sun visors you came up with, the stock ones really suck since they are too short. Do you think low hanging branches might get stuck under the front of the solar panels?

I looked for sun visors that slid on the rod, these are 2003-2009 4 runner visors that happened to also come with the second visor that just folds down. I also started with the over head console you can buy from like jc wittney, aluminum piece that attaches to the factory visor mounts and cover with a gray felt type material. I used that as the skeleton for the new console and taped new holes for the 4 runner visors. I'll get some pictures of them in action

My two front panels sit on top of the roof rack and under the roof rack wall/lip, so yes branches could get under the roof rack a little but would not make contact with those panels unless it was from above. The two panels on the cargo carrier sit at 10' 10" so I expect them to get scratched if I decide to go somewhere with a lot of over growth.

[luked]

Originally Posted by boywonder

excellent!! Really digging the Harbor Freight roof rack....tell us a bit more....

Are those aluminum loading ramps bolted together? Brialliant!!

Yes, they are the $99 tri-fold ramps, I used three sets, three trips to HF with 20% off coupons so $80 per set. I saw the idea on pirate 4x4 I think, just google "ATV ramp roof rack" and you find someone who came up with the idea, I just refined it for my usage, and the measurements were spot on for this top.

I am not a welder so I bolted them together with 1/4" grade 8 bolts in various places. then I used 3/16" x 4" aluminum flat bar for the edge/exterior wall, riveted in place and bolted through. I used 1/8"x 4" flat bar for the 5 legs per side, the rack sits on top of the legs to put downward pressure instead of stressed on the sides, plus it made for a more vertical mounting angle. On the inside of the top I used 3/16" x 2" flat bar as a back plate the entire length of the rack mounts. I removed a few of the "steps" in the corners to get the flat bar to naturally curve around the corners.

I used a 90 degree angle drill also from harbor freight to get in the tight space, best pictures I have

[luked]

Originally Posted by Bbasso

Fantastic.

But just one question, why that type of water heater?

Suburban SW6DE propane/electric with electronic ignition

[rallypanam]

Really nice work. Congrats!

[bigriver]

Wow - tremendous effort. Hope to meet up out there somewhere and see it in person... congratulations

Joe

[1der]

Luked - super nice execution and documentation! Looking forward to seeing it one of these days!! Enjoy 😊

[Smoker]

Really nice build. I appreciate all the pics and description too as I'm just about to start mine, also a 15 passenger. Mine won't be as nice, but I'm inspired. Thanks

[MSD]

Holly Cow!! Very inspiring build Luke. Looks amazing… Out of all the tops I've sold your van looks the best thus far...
I just got extra motivation to get our van finished. Thanks for the motivation. I'm gonna keep coming back here every time I start to get burned out.
Job well done!