The Gnarhauler: Another white cargo van.

[aarcaris]

Originally Posted by ibike

Interior panels are all wrapped and mostly complete, need to fine tune a few of the seams between panels and get more mounting hardware but the hard part is done! Next up, boxing in the electrical components around the passenger wheel well. Attachment 38572

It looks great!

[ibike]

Originally Posted by mothgils

That looks great man!

What did you end up doing to cover the transition from the roof to the wall?

Thank you. I cut some strips of 1/4” melamine and used some long 1/4-20 screws along with rivnuts in the sheet metal to hold them in place. I put a round over on the front edge then wrapped them in foam and fabric.

[ibike]

Lights all hooked up. Also started framing the passenger wheel well box out of 8020 as well.



Got some great days in at AZ Snowbowl this season. Van makes a great mini-lodge.

[JoeH]

Originally Posted by ibike

Got some great days in at AZ Snowbowl this season. Van makes a great mini-lodge.

Turning out to be a decent season all things considered.

[ibike]

Originally Posted by JoeH

Turning out to be a decent season all things considered.

For sure, with another foot in the forecast this week!

[ibike]

Haven’t posted updates in a while, but I’ve been hard at work.

Finished framing the wheel well boxes with 8020. The driver side will be the home of a water tank and heater eventually.



Both boxes got skinned in 3/8 birch ply, then covered in the same coin material as the floor.



The aluminum l-metal at the top serves as the foundation for a three panel removable bed system. I had a local fab guy make me three identical frames out of 1” aluminum square tubing.


Each panel has a retractable spring pin on both short sides that index into holes in the aluminum l-metal on the wheel well boxes that keep everything in place.



Next I got a 4” foam mattress topper from Amazon, cut it onto three equal pieces and upholstered to 3/8 plywood panels that got attached to the aluminum frames. I was in the zone and didn’t get any pictures of this step of the process.

Here’s the almost finished, but useable end result.

Panels in place.



Panels stowed. I ended up storing two panels end to end on the driver side as to not eat up to much width in the van.


All the toys with a comfortable bed in tow. Nice to get up off the floor!!


I need to finish the tops for the wheel well boxes and break down the bed panels and l-metal to get it all powder coated, but I’m happy with the outcome. I’ve already got about a dozen nights in the bed so far this summer.

[Mike Clements]

I like the looks of this. I just got my van and will be starting the interior build out soon. I may steal some ideas from you here. I can appreciate beautiful cabinetry, however, I like the utilitarian easy to clean vibe you have a lot.

[ibike]

Got a few good trips in over the past month or so.

Colorado, Uncopaghre Plateau and Rico for some moto. Put two dirtbikes inside the van and pulled my buddies expo trailer with the van. This configuration is really making me consider 4.10 gears….





Quick weekender to the White Mountains in northern AZ to ride the only lift access mountain biking in the state. Not much of a bike park, but the trails are raw and rugged which is what I prefer.






Colorado again, this time Durango. Rented a condo with some friends. Did a few dirt bike rides and some mountain biking. Got a new rack from Bolt It On for inside the van, also got a Transit jump seat I purchased mounted up. We got two dirt bikes and three mountain bikes (bars turned, pedals removed) inside the van, and put a third dirt bike on a hitch carrier out back.






Making a punch list and wish list along the way as I use the van and figure out how to improve usability.

[ibike]

Got my door panels wrapped up recently.

Made insert boxes out of 1/2” plywood and lined with speaker box carpet





Removed some sheet metal from the door to maximize space. Mounted the box with some 1” aluminum angle, covered the bottom 2/3 of the openings with bungee netting.




Then I made skins out of 1/8” plywood, wrapped in 1/8” foam and covered in marine vinyl.



Finished product

[marret]

Nicely done, looks great.