Gruffalo the Family Adventure Van - Build Thread

Jboles

Senior Member
Joined
Apr 15, 2015
Posts
104
Location
Chattanooga, TN
Hello everyone, I'm new to the forum. I'll have to say thanks to all the contributors and moderators for making this forum possible. What an excellent resource.

We recently (finally!) purchased a new to us van to build out for an adventure van to haul our family to rivers and mountains. We are located in Tennessee and we do a lot of weekend trips mostly to nearby whitewater rivers and creeks. We also wanted a van for longer cross country trips.

We bought a 2006 E350 XLT Super Duty with a high top. It was a wheel chair transportation van in it's previously life in Wisconsin, however we bought it via NC. I didn't discover this forum until after the purchase and we sort of feel into buying a van with a raised top, luck? We shall see, we think so. We knew we wanted an extended passenger and decided we wanted the Ford e-series with the 5.4L gas.


Here was a photo of the drive home after picking up the van near Asheville, NC.

The high top was installed by an outfit in Oklahoma that does these wheelchair vans. It has a stout steel roll cage between the headliner and the fiberglass top. With the roll cage we loose about 3-5" of head space inside the van. Not crazy about it but more on that later.

The van has 173,000 miles but mechanically seems well taken care of. The interior was dirty as all heck and has been smoked in. Needless to say it is currently getting a deep clean. Good thing I used to detail cars back in college.

Did I mention we are building this on a tight budget. We wanted to stay in the $4 to 6k range for the initial purchase and we got this van for $3,800. We feel like it was a fair price for the mileage but that's a lot of van for under $4k so we are happy with it so far.

We plan a simple build that will fit at least four passengers, we have a 2 year old and 70 pup that will be travel with use on most trips. At this point our basic plan is as follows: platform bed in the back with a permanent queen size bed with storage underneath. Two bucket seats or a double bench seat in front of the bed with a cabinet, fridge, storage behind the drivers seat back to the bed. A permanent bed is a must for us at this point. We want to make those weekend trips easy and not having to situate gear, move this, move that, unfold this, latch that, unfold the mattress, get the bleepin sags, etc. We just want to pull in the campground, put the kid to sleep and hit the bed - if needed. Anyway, more on the build later. Here are some more photos.









Shampooed the headliner trying to get the smoke smell out.


The license plate was riveted on so had to remove, drill them out and install my new plates.


I ordered a new OEM carpet from Fam Van Parts for a $100, $150 shipped. It's not the permanent set up we want but it was cheap and quick as we have a trip coming up in a couple weeks. It's plush and gets us by until we figure out our final build flooring. The plywood with rubber flooring on top of that which I've seen on the forum looks good and reasonably priced and easy to install.


Current set up


Will build a bed platform in the back soon as temporary measure for our upcoming week long trip. This will help us figure out what we need for a long term set up. I'm hoping to get it high enough to put our mtn bikes on fork mounts below, approx 32" clearance. The total ceiling height is about 60 to 62 inches. Will have to sacrifice head room while sleeping if we want that much storage.


First kayak trip to one of our local runs. Considering a rack on top eventually for whitewater boats. Not sure how that would work or about accessing. We shall see.


I'll try to post back when I can with updates on the build. I plan to keep it 2wd but will consider a posi-track or limited slip differential if I determine that would help with the conditions. I typically won't need 4wd as we mostly need clearance for rough putin roads but most the time 2wd is fine.

Well, I hope to hear any all feedback and input. I need all the help I can get.

Thanks,
Justin
 
Indeed welcome to SMB! Nice looking van with great potential for the money----you did well I think. Were it not for all those windows (not needed or wanted for my use) that would have been a deal I'd have jumped on my own self! a few observations that hopefully are helpful........

The heavy roll cage-like structure just under the raised roof is absolutely necessary if only from a Federal Motor Vehicle Safety Standard for after manufacture vehicle modifiers. Factory roof structure removed while adding that top renders the body very fragile----properly designed and installed those upper cages restore a lot of upper body rigidity.

Along that same line the rear doors have better upper latches---earlier versions of extended-height doors similar to yours didn't have that feature. I have one of those and the doors aren't don't close as solidly as I'd prefer.

If this van has been properly maintained over its life those 173K miles is almost nothing. My own 2000 E250 was purchased with 203K miles, now has just over 275K miles and has been pretty much flawless since 2008. Not sure your DIY skill or interest level but most of us here along with another site can pretty much walk you through many steps that will save money and give great peace of mind small repairs/maintenance is done correctly.

If the stink of previous smokers persists fire restoration companies that mostly specialize in residential work regularly treat vehicle interiors too. Its an ozone-replacement process that's not too expensive over all but is so thorough its well worth the cost, typically less than $200. By way of a "fogging" process it reaches spots inside we can't even see.

Anyway hope to see your progress. :a3:
 
Welcome from another Tennesseean! :b5: I'm just up the road near Knoxville. Looks like you got a good deal and a good start. Nice to see that high top with rear air too, that's a fairly rare combo. You'll need it with our humidity.

Looking forward to the build.

:a4:
 
Welcome Justin! Looks like a great budget van.

As mentioned, ozone is the method of choice for removing the smoke odor. My buddy works at a place that does home repairs for insurance companies, mostly smoke and water damage stuff. They use ozone on lots of things from house fires, and it works amazingly well.

We love pictures here, so keep 'em coming!

:a4:
 
Thanks everyone, looking forward to figuring out what will work best for us and putting it into action.

JAW - same JAW over on the Ford Enthusiast forum? You and others gave me some good input on a DCT 0446 code just last week. And yes, plan on doing most anything myself so I'll be sure to ask and post up anything that may be of interest. I've already fixed the brake lights and check engine light (needed that to pass emissions and get tags). -Thanks for the input on the roll cage, I figured as much but haven't seen anything as stout at this on other hightop or poptop build threads. I haven't personally investigated many of them in person.

I'm familiar with the Ozone process. We used to use one when I worked at a Toyota dealership back in the day. I may have to go to that extent, we'll see. Plan to replace the bench seat and possibly the front seats as well. If it's still an issue after that I'll consider the Ozone.

Good to see some fellow southerners on here too. Super cool.

Regards,
J
 
Jboles said:
Thanks everyone, looking forward to figuring out what will work best for us and putting it into action.

JAW - same JAW over on the Ford Enthusiast forum?

J

One and the same----some of us are here and there too----and awesome too! :a1:

BTW its JWA not JAW! :a3:
 
JWA - good deal. Small world around here. Also, regarding the window vs. cargo van. My wife straight up said she wouldn't drive a van without windows so we quickly moved in the direction. I'm ok with it but see where you could install enough windows in the right places on a cargo van and get about the same. None-the-less, we like what we ended up with.


I was able to get a few things accomplished this weekend. Very luckily I picked up a used swing away bike from a local gear swap. I wasn't even looking for one quite yet but for $200 I couldn't pass it up. I don't favor having bikes on the outside of the van but it will be great for those long trips where we need the interior space and simplicity of having the bikes secured outside the van.






I also picked up a roll of Reflectix and cut out some window blocking inserts for when it's super hot and sunny and for sleeping. We plan to lay them out for all the window except the front where we plan to install a full width curtain behind the captains chairs.





I bought lumber to build the platform and a few other items before my trip coming up in two weeks. I got two 4x8 sheets of 1/2" plywood and a dozen sticks of 2x3s. I hope to build up the platform in the next week or so. The interior smells like lumber for now - much better than some old cigs.

Regards,
Justin
 
Build update:

Our first trip is coming up next weekend and the van is just about ready. I'm finished with the bed platform, got the windows tinted and put a coat of spray paint on the steel wheels. I also built a removable platform that fits over the bench seat up to the back of the front seats seats for my boy to sleep on. I'm 90% complete with the cleaning of the muck that came on this thing. A few door panels and the dash is all I have left. It's been fun but a lot of work leading up to our first trip.

The bed platform has 27" clearance below the 1/2" ply board to the carpet, about 33" above. We will put a futon mattress with a 2" memory foam mattress topper on top of that.

















 
Looking good!

Hey, I just realized something. The first pic of the snow capped mountain, on your way home from getting your van. Isn't that the first lookout for Mt. Leconte just up from Sugarlands in the GSMNP?

:b5:
 
Scotty, you nailed it. We took a quick detour as we were passing through Gatlinburg towards Townsend on our way back to Chattanooga. We had planned to go up over Newfound Gap and through the south side of the mountains but the tourists were too slow and we were ready to get home. Stopped at this spot and turned around.

Good eye!

Justin
 
That bed looks nice and big! Is that going to be a permanent fixture in the back of your van? I noticed you made wider than the opening of your doors.
 
Racer,
Yeah it's a permanent bed. A lot of the traveling we do is short trips on the weekends so having a permanent bed that is always ready was paramount for us. We didn't want to have to move a bunch of gear, fold down this, put that away, store this outside, etc, to set up the bed. Also, I'm 6'3" so I need some room.

I have a trailer I use if I need haul anything that is tall, etc. so I'm not planning to remove the bed routinely.

Ultimately, we wanted to sleep in comfort as well. We should have that covered.

Thanks for the reply,
Justin
 
Greetings from another Southerner, Atlanta.

You know, home builds always end up being my favorites to see. And I like what you've done based on your criteria. My son and I take off for short trips sometimes and messing around with all the bed making drives me crazy.

Based on what you've just done, do you think there's enough room height wise to do some type of bunk bed system? Meaning 2 sets of bunk beds with heads at the back door and feet toward the front.

I'm trying to sleep 4 with a permanent bed system since on short trips we spend basically all of our time outside.

Good score on the van and nice work on the restoration. Hope to see it out camping nearby some time....
 
Nice find.
I too kayak a lot... but keeping my 12.6 ft kayak inside wasn't very pleasant so I have it mounted on the roof. I also have a high top and it does pose a problem with accessibility but using a cargo tray in the rear receiver is the key to loading/uunloading easily.
I'm sure if you search my gallery, I have pictures of my setup.
Welcome to the forum.
 
Ultralite - there is definitely enough room to sleep under the platform. I have it set up with about 25 inches clearance below so that could work out just fine. I use the cross members to bolt to the floor so you'd have to set up some sort of plyboard floor fill in the space between.

Update on the build and so forth:

We took our first trip in the van. We drove about 1800 miles in 10 days or so. The van did great nothing weird or unexpected happened aside from a very annoying squeak coming from the front left at highway speeds. I need to get that figured out but otherwise the van is doing very well. The main bed was awesome and small bed we made for our toddler worked out well. We used the van as a mobile bedroom this weekend to stay over at a friends house close by, great for a family with a young child so you don't have to be home at 8:00 to put the kid down.

Here are some photos:









 
Quick build update:

My passenger seat swivel was finally delivered this week and I got it installed. It's amazing how much more living space this adds to the van. I also tested out the location of the custom seat I would like to install. By unlatching the factory bench seat and moving it back against the bed it gave me a good feel for what the living space could be like. More on this later...

Here are some photos with the swivel installed.

I'm going to drill a hole in the base for the airbag sensor pigtail plug to fit through. And will cut one of the plugs and extend the wire long enough for the seat to swivel. I'm hoping this doesn't cause any sensor signal issues (anyone have experience with this?) Right now I have to unplug the sensor each time I swivel it around.













My plans for the custom seat involve buying some take-out seats from another vehicle. Something with a back that folds down flat. Likely something out of a mini van or SUV. Here are two possibilities I'm been looking at lately, see links below. I'm planning a cabinet behind the driver seat back to the bed that will include a fridge, possibly water and other storage, kitchen storage, etc. So one seat would be against the passenger side, one in the middle of the van. (Anyone with success doing this?) I'll be having a friend weld up some mounting brackets and most likely some stiffener plates below the van. Should get interesting.

I plan to use the factory seat belts, one of the factory shoulder belts on the passenger side is in the right place and likely a lap belt in the middle seat - at least for now. Seat belts internal to the new seats would be ideal.

http://www.ebay.com/itm/2-new-GRAY-LEAT ... cb&vxp=mtr

http://www.ebay.com/itm/set-2-BUCKET-SE ... 6363&rt=nc

Cheers,
Justin
 

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