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Old 12-31-2018, 04:03 PM   #1
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Join Date: May 2014
Location: Scottsdale, AZ
Posts: 225
The Gnarhauler: Another white cargo van.

This is a duplicate thread to one I've started over on Expo Portal, but wanted to add a thread here as well since I've gotten a lot of inspiration from this site. I'll do my best to keep both threads updated in tandem. Anyway, on to the van!

First, a little behind the intent of this build. I'm a mountain biker, dirt biker, camper etc. I need a comfortable, secure way to transport myself, a few passengers and our gear to and from destinations while also offering somewhere to sleep and shelter from the elements. This will be less of a dedicated camper and more of a flexible, configurable gear and people transport.

I've been drooling over SMB/4x4 style Ford vans for some time now, I've always wanted to build one of my own. A little over two years ago I was ready to pull the trigger on a used cargo van to start converting, then I got cold feet. I ended up buying a brand new Tundra TRD 4x4 with plans to build it into an expo/overland style vehicle. I was really enjoying the truck and getting some modifications done to it. As time went on and I used the truck, I was quickly getting over beating up a brand new vehicle that I was still making payments on. The idea of a van was still burning in the back of my brain.

I put the Tundra up for sale this May, sold it private party a few weeks later and then began my hunt for a used van. The requirements for the van were: rust free, cargo van, EB, V8, sub-150k miles, sub-$10k, PW/PL and cruise control. After some searching, I came across a van that checked all the boxes minus CC. A 2006 E350 EB cargo. One owner with 125k miles on the clock. After some research I determined it would be an easy enough to add cruise later. I began the negotiation process with the seller and soon after was on a plane from Phoenix to San Jose to pick up my new-to-me van.

Van wishlist
AT tires-Complete
Small lift/suspension-Complete, for now.....
Floor with cargo tie down and seat attachment points-Complete
Passenger bench-Complete (may add third row if needed)
Roof fan-Complete
Aux battery-Complete
Cruise Control-Complete
Roof rack-Complete-ish
Insulation
Interior paneling
Power distribution
Interior storage
Stowable bed platform
Stereo-in progress
Solar panel
09+ front seats w/swivels
Awning
Solar shower
Cargo box

Picture of the van from the CL add.
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After a test drive and through inspection I was on my way back to Phoenix. I made to over 700 miles home in one shot, van did great. A little front end wobble around 65, I assumed due to worn out front end components, cruise control sure would have been nice.....
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Got the van home and did some interior cleanup in preparation for starting on CLD (constraint layer damper, AKA Dynamat) treatment of metal surfaces.
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Also made up a quick set of Reflectix window shades to protect the interior from the harsh AZ sun. I used metal tape to attach some small magnets around the perimeter to hold the shades to the metal window frames.
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Took care of some necessary maintenance along the way. New Moog tie rod/dragling assembly, replaced a balljoint, oil change, coolant flush, AC recharge, new fluid and dif cover seal and an alignment.

Of course, the mandatory van right of passage. Step one, put a hole in the van.
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Step two, put a fan in the hole. I used the Hein adapter off Ebay, if anyone is wondering.
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Picked up a group 31 100ah deep cycle AGM battery to power said fan and other accessories. Found a nice steel battery cage online and used some 3/8" grade hardware to hang it off the crossmember. I went with the X2 (Batteries Plus house brand) because of the 4 year warranty. Phoenix heat is not kind to batteries, and if I do need to replace it in 18 months, it'll be nice to not have to pay for it.
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Until I got a floor in, this was my makeshift method for hauling my 250 XC-W around.
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Van out in the wild doing van stuff. First shakedown to the White Mountains and Sunrise Ski Resort, the only lift-acess mountain biking in AZ. The bike is an Evil Insurgent for those who may be wondering. That was the first time I'd ridden it since I built it up, absolute ripper with a 170mm Lyrik on the front.
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Old 12-31-2018, 04:18 PM   #2
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Join Date: May 2014
Location: Scottsdale, AZ
Posts: 225
Slept in the van for the first time that weekend, simple Ikea twin mattress on the floor. Works for now till I figure out a bed platform.
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Back to work, began adding FatMat CLD all over large, resonant metal surfaces. The plan is to install L-Track in the rear for seat tracks and cargo tie down points. Using masons string to mock up potential locations.
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Treated the front doors as well, they got the full sound treatment including a sheet of mass load vinyl backed with closed cell foam. I swapped the factory paper cone speakers for a set of JL Audio 6.5 components while I was in there. Tweeters got installed in the black sail panels on the backside of the rearview mirrors.
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Picked up some Moog 880 coils for the front and Bilstein RV comfort series shocks for all four corners.
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The tires that were on the van had lots of life left, but were pushing five years old. Swapped them out for a set of Falken Wildpeak AT3W in a 265/75R16, including a full size spare. (Which does fit in the factory location, BTW)
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Not a big fan of the dog dish hub caps, so I ditched them and rattle canned the wheels satin black. Much better.
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The van is still doing van stuff with all the projects underway. One dirtbike and two full size arcades, very happy with my decision to go with an EB.
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Post-pedal in Flagstaff.
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Old 12-31-2018, 04:28 PM   #3
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Join Date: May 2014
Location: Scottsdale, AZ
Posts: 225
Along the way I picked up a cruise control wheel from the junkyard. Ordered new buttons and clock spring, ended up having to replace a faulty brake pressure sensor switch as well. One of my mountain bike buddies is a Ford master mechanic, got him to enable the speed control option in the ECU.
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SUCCESS!!
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I picked up a pair of brand new two person Transit bench with built in seat belts off CL for $50 each. Going to use the legs of the seat to set the L-Track spacing.
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Ordered some recessed L-Track and used the Transit seat to create a mounting placement jig.
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Heres the idea, right or left seat placement depending on how the vans being used.
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Three sheets of 3/4" ply, laid sideways and rough trimmed using the factory rubber mat. I covered all side of the ply with deck sealer to prevent moisture issues down the road.
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L-Track test fit.
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Last step before plywood goes in, 3/8" neoprene foam in the low point of the corrugated floor. Hoping to get some noise reduction and insulation out of this, as well as sure up the plywood.
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Old 12-31-2018, 04:34 PM   #4
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Join Date: May 2014
Location: Scottsdale, AZ
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Joined the plywood pieces with wood glue and dowels to prevent heaving at the seams.
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Floor in the cab got the same treatment as the doors, 100% CLD coverage topped with closed cell foam and mass load vinyl.
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I looked at a bunch of flooring options an opted for rubber coin. Home Depot sold some online that came in a 7.5'x17' roll, enough to cover front to back and side to side in one piece. I didn't get many pictures of the rubber floor install as I was under the gun to get the floor wrapped up and seat installed for a snowboard trip over Christmas.

From the rear, with tracks and aluminum threshold installed.
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Side step detail.
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Transit seat mounting detail, hacked off the factory brackets and had a buddy weld on some 2"x3/16" tabs. i also installed steel backer plates under the van where the track bolts through in locations where I plan to mount the seat.
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Transition from the plywood floor, I put a taper on the leading edge of the plywood to help ease the transition.
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Old 12-31-2018, 04:40 PM   #5
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Join Date: May 2014
Location: Scottsdale, AZ
Posts: 225
A few more goodies from along the way. Picked up a 45qt Whynter fridge, fits nicely between the front seats. Just plugging into the CLA portin the dash for now. Planing on building a fridge slide to attach to the L-Track at some point.
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Amazon lightbar and sprayon bedliner bumper.
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New to me head unit with car play. Popped out one of the lighter plugs on the dash and replaced it with a USB bulkhead I picked up off Amazon, connected directly to the rear of the stereo.
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More van in the wild photos. I scored a free aluminum ladder rack off an old Econoline we retired at work. Refinished it with rattle can bed liner and some flashy grade 8 hardware. Plan on using it as a foundation for an awning, solar shower, cargo box and solar panel to charge the house battery eventually.
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Christmas day at Snowbowl. Quite possibly the first time the van has ever seen snow in its life.
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Old 12-31-2018, 04:43 PM   #6
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Location: Scottsdale, AZ
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Low hanging fruit.

Busy few weeks with the holidays, managed to sneak out for a mountain bike ride in Sedona yesterday. High of 50 degrees and snow still in the shaded areas [emoji51] [emoji3587]

I quickly realized I need to better way to transport mountain bikes in the back of the van.

I really liked the look of the 1-Up van tray mounts, but at $75 each I investigated some more cost-friendly options. I went to a tried and true design that’s been around for a while, the good old PVC bike rack. Modified slightly to fit my needs. Link to plans if anyone else is interested
https://www.utahmountainbiking.com/g...edBikeRack.htm

I determined spacing to give enough room for handle bars with some wiggle room built in for sway. I had originally hoped for room for four bikes, but three ended up pushing it.

Needed a method to attach to L-Track. Went to Lowe’s and got some 3/8” x2” carriage bolts, finessed the heads with a flap disc till they easily slid in and out of the track.

I had ordered some thumb screws off Amazon a while back for this very application. Installed the 3/8 nuts I bought along with the carriage bolts into the thumbscrews.

Centered the rack in the van and marked where the rack would meet the tracks.

Now my bike is riding in style, only takes two minutes to take the rack in and out. Pretty happy with the results, I’m using a 24” bungee from the handlebars to the top crossmember of the rack to keep the bikes from rolling out backwards. Center bike will need to go in backwards and get secured by the seatpost.


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Old 12-31-2018, 05:51 PM   #7
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Garage
Nice, well done.
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Old 01-10-2019, 05:16 PM   #8
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v nice. I love Snowbowl!
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Old 01-10-2019, 05:44 PM   #9
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Me too but I live here. Crazy busy over the holidays.
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Old 01-10-2019, 08:55 PM   #10
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Good job on build I like your style..
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