Gruffalo the Family Adventure Van - Build Thread

[arctictraveller]

Lonseal is a great product, I've used lots of it in commercial marine applications on outside decks. It wears like iron and does not fade in sunlight. It's a good choice.

 

[Goneagain-SKO]

Ive been looking at lonseal also. Epoxy? wow! that is intense.

 

[Jboles]

Test

Test

 

[Jboles]

Progress

I've been woefully bad at posting progress on the van build. I'm going to post a series of photos to try to get this build thread back up to speed. I wish it were easier to post photos to this forum.






Flooring complete

Fold down barndoor table with shelf






Spray painted the chrome grill and front bumper


New toys! Two Lifeline 31XT AGMs, 125 AH each


Junkyard step bumber, $60, rattle can bedlinered

 

[Jboles]

More build photos

Drivers swivel

Door talon

Rear barn door window swap

Temporary battery and ACR install. I couldn't help myself. I'm planning to mount the batteries on the frame but I wanted to get them installed to see how things would work. Still need to be build the batter box/mount for the frame rail.

Mock up for batter box mount below the barn doors

A couple of action shots.



Step bumper from a construction fleet van, full of grout

Wet sanding the front bumper before final paint

Removal of the rear barn door window. Turned out great.

 

[Jboles]

I've been woefully bad at updating this thread. I'll try to post some photos on the progress. Here is a quick list of updates.


Cooper AT-3s, Stock 245 65 16
Roof deck
Solar, two 100W panels, MPPT charge controller, 30A
Two lifeline 31XT, 125AH each, mounted on custom built battery box on the frame behind rear axle. (Finally have a welder)
Trap door gadget box under the bed behind the rear bench seat. This holds the following so far: Blue Sea ACH (remote switch under steering wheel), DC fuse panel, grounding bus. Future location of charger/inverter.
IndelB 51qt chest style frig/freezer still going strong.
Rear pop-out windows
Water system: 20 gal tank, water pump, hose and sprayer out the back
New front steering linkage from steering box to each wheel, alignment, then I got the new tires.
Some various insulation, mostly just reflectix. Need to add thinsulate before paneling.
I'll post some photos next.

 

[BCam]

Your photos have been very helpful. I recently purchased a very similar 2005 E350 but with the lift door in the side. With that exception, it looks like our tops are identical and I've been wondering what's under the headliner, which looks the same, and how/where to install a roof vent.

My wife is in a wheelchair so we need the lift, which limits what we can do, but my plan is a minimal conversion (bed, potty, microwave). I'm recovering from rotator cuff surgery, so it will be a while before I can get to work on it.

Here's a photo of mine:

Sportsmobile Forum - BCam's Album: 2005 E350 Wheelchair Van - Picture

 

[Jboles]

Your photos have been very helpful. I recently purchased a very similar 2005 E350 but with the lift door in the side. With that exception, it looks like our tops are identical and I've been wondering what's under the headliner, which looks the same, and how/where to install a roof vent.

My wife is in a wheelchair so we need the lift, which limits what we can do, but my plan is a minimal conversion (bed, potty, microwave). I'm recovering from rotator cuff surgery, so it will be a while before I can get to work on it.

Here's a photo of mine:

Sportsmobile Forum - BCam's Album: 2005 E350 Wheelchair Van - Picture

Awesome! Yes, sir. Same top. Sweet van!

 

[BCam]

Thanks, I'm chomping at the bit to get to work on it.

When you were mounting your roof vent, did you consider trimming the upper and lower trim flanges so they'd straddle the roll cage pieces rather than modifying the roll cage? The bars may affect the airflow a bit but I don't think it would be too intrusive.

We have a motorhome with a lift so this will be for those times that the motorhome is overkill. It's not a typical Sportsmobile forum project but this forum seems to have the best and most relevant information on van conversion.