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Old 11-25-2015, 07:31 PM   #81
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Re: 2010 Express AWD build,The Gnarvan

Added final layer of insulation. (Thermozite)

Finished wall panels going back in around gray vinyl trim pieces to match factory plastic trim.

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Old 11-25-2015, 07:35 PM   #82
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Re: 2010 Express AWD build,The Gnarvan

Assembled cabinets going in with lots of prewiring.


Tan vinyl added to wall/ceiling trim piece and installed.
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Old 11-25-2015, 07:42 PM   #83
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Re: 2010 Express AWD build,The Gnarvan

Started on counter top.

Sticking the laminate to the board.

Trimming the laminate.
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Old 11-25-2015, 07:46 PM   #84
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Re: 2010 Express AWD build,The Gnarvan

Adding the bull nosing

Counter assembled ready for install.

And installed.
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Old 11-25-2015, 07:58 PM   #85
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Re: 2010 Express AWD build,The Gnarvan

More of counter and cabinet.

And after ordering a 10 gallon water tank from Amazon that showed up and looked like a quality tank, but didn't match the described dimensions at all. I am still waiting to hear back from the seller A1Customs. So I called Ronco, and Rich was able to expedite an order for me and in two days I had a 12 gallon tank that fit perfectly in my space at my door. I also had a 4" top inspection port that could also be used to fill the tank with jugs. the price was about half of that listed on there website.

With the Webasto in and wired it was time to make the fuel connection. So I dropped the fuel tank and added a pickup tube.
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Old 11-25-2015, 08:03 PM   #86
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Re: 2010 Express AWD build,The Gnarvan

I also made the frame bracket for the 8D AGM battery.


all painted and ready to go in.
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Old 11-25-2015, 08:07 PM   #87
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Re: 2010 Express AWD build,The Gnarvan

More battery frame and battery going in.



I need to take some better pictures of it in place and all the wiring.
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Old 11-25-2015, 08:15 PM   #88
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Re: 2010 Express AWD build,The Gnarvan

With a water tank it was time for some plumbing. I started by cutting the holes in the floor for the coolant lines going to the heat exchanger. I used 3/4" waterproof strain reliefs for the pass through. I used the same ones for the #2 wire coming in to the inverter and 1/2" for the 120v incoming wire.

Here is the start to the plumbing. 1/2" copper to connect silicone coolant lines under the van up to the heat exchanger in the van. I used 1/2" pex for water lines. The silver valve is a tempering valve to keep the hot water at a tame temperature.

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Old 11-25-2015, 08:20 PM   #89
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Re: 2010 Express AWD build,The Gnarvan

More plumbing. Drain valves, hot, cold, and tank, these will get tied together and ran through the floor with 1/4" tube.


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Old 11-26-2015, 08:14 AM   #90
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Re: 2010 Express AWD build,The Gnarvan

Nice! You've been busy.......are you using cherry plywood?

The strain reliefs for floor penetration are a great idea.
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