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I picked up this decently optioned LS 6.0 powered 2006 Chevy Express 3/4 ton van for a pretty good price. I have been wanting to do this project for a while, but have been looking for a while for the right deal on a van. I wanted to have a van with traditional doors on the side rather than a slider, but this is what came available. It is a completely gutted cargo van, with a divider installed. https://www.AR15.Com/media/mediaFiles/183526/0407192015_jpg-912062.JPG Sorry, I didn't take any pictures of the gutted interior. But you can imagine a bare van. This is after insulating the van and adding 1x3 strips to work off of. https://www.AR15.Com/media/mediaFiles/183526/0409191812_jpg-912067.JPG https://www.AR15.Com/media/mediaFiles/183526/0407192016a_jpg-912072.JPG At this point I decided against sheeting it with plywood as I had originally planned. I went with a layer of Reflectix thermal barrier. https://www.AR15.Com/media/mediaFiles/183526/0413191439_jpg-912073.JPG Followed by vertical strips to accommodate the wall material. https://www.AR15.Com/media/mediaFiles/183526/0413191618_jpg-912074.JPG Wall material is Pine T&G. https://www.AR15.Com/media/mediaFiles/183526/0413191750a_jpg-912076.JPG Process is the same on the other side... https://www.AR15.Com/media/mediaFiles/183526/0413192023_jpg-912077.JPG The bulkhead and floor will be insulated and sheeted in cedar. The area in the rear that is nott sheeted is where the bed frame will be built. I am still trying to plan out the ceiling, I have it furred and bowed, The final product is being thought out as I go. Power will be a combination of 200 watt solar and a couple inverters with a bank of two 12v batteries. The inverters. https://www.AR15.Com/media/mediaFiles/183526/0314191857a_jpg-912080.JPG https://www.AR15.Com/media/mediaFiles/183526/0319191905_jpg-912082.JPG More pics to come. ETA: The van was 3000 dollars and as of this post 400 in materials. Goddamn You are in my head. I’ve always wanted to build something like this: |
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Your bed looks designed for the sleeper's body to be orthogonal to the long axis of the van. That will be cramped. 
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A bit of small work today. Sanding, installing door and drawer hardware, installing cabinet floors and drawer bottoms, lighting and more insulation on the floors in the storage areas. https://www.AR15.Com/media/mediaFiles/183526/0421191826_jpg-920703.JPG https://www.AR15.Com/media/mediaFiles/183526/0421191442_jpg-920707.JPG https://www.AR15.Com/media/mediaFiles/183526/0421191918_jpg-920708.JPG https://www.AR15.Com/media/mediaFiles/183526/0421191846_jpg-920709.JPG 
I hope it was free.
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I'm just assuming that unless he's 5'3" he's probably going to put a collapsible platform towards the front of the van and use an air mattress. I'm 6'3" so I kind of make some assumptions. But I know I wont have too much issue if I don't. I am only 5'5''. The bed measures 5'9''. Not a lot of wiggle room, but it is longer than the 5.5 pickup bed I usually sleep in on the trips this is aimed for. Had I found an extended van for a reasonable price, I would have put in a full size bed. Maybe in another build in the future.
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Gold hardware?
I hope it was free. Quoted:
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A bit of small work today. Sanding, installing door and drawer hardware, installing cabinet floors and drawer bottoms, lighting and more insulation on the floors in the storage areas. https://www.AR15.Com/media/mediaFiles/183526/0421191826_jpg-920703.JPG https://www.AR15.Com/media/mediaFiles/183526/0421191442_jpg-920707.JPG https://www.AR15.Com/media/mediaFiles/183526/0421191918_jpg-920708.JPG https://www.AR15.Com/media/mediaFiles/183526/0421191846_jpg-920709.JPG
I hope it was free. |
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I have been thinking about possibly doing something like that. But I know I wont have too much issue if I don't. I am only 5'5''. The bed measures 5'9''. Not a lot of wiggle room, but it is longer than the 5.5 pickup bed I usually sleep in on the trips this is aimed for. Had I found an extended van for a reasonable price, I would have put in a full size bed. Maybe in another build in the future. Quoted:
Quoted:
I'm just assuming that unless he's 5'3" he's probably going to put a collapsible platform towards the front of the van and use an air mattress. I'm 6'3" so I kind of make some assumptions. But I know I wont have too much issue if I don't. I am only 5'5''. The bed measures 5'9''. Not a lot of wiggle room, but it is longer than the 5.5 pickup bed I usually sleep in on the trips this is aimed for. Had I found an extended van for a reasonable price, I would have put in a full size bed. Maybe in another build in the future. |
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It appears my eye needs calibration then. Is it 5'9" front to back or side to side? Quoted:
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I'm just assuming that unless he's 5'3" he's probably going to put a collapsible platform towards the front of the van and use an air mattress. I'm 6'3" so I kind of make some assumptions. But I know I wont have too much issue if I don't. I am only 5'5''. The bed measures 5'9''. Not a lot of wiggle room, but it is longer than the 5.5 pickup bed I usually sleep in on the trips this is aimed for. Had I found an extended van for a reasonable price, I would have put in a full size bed. Maybe in another build in the future. 
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I thought this picture looks neat.
I took it last night after a good bit of sanding and Gettin all the lighting in and lit. Plenty of light in there. Attached File |
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<-- RV, trailer, custom camper tech in a past life..
I've worked on many van conversions, RVs, assorted trailers of all descriptions, as well as built campers from the ground up starting with a bare frame on a new vehicle.. A few comments I hope will help. I noticed magnetic catches on the doors below the bunk... One good bump or a hard braking and they'll pop open. Go for something that positively latches / locks.. I had a Ford extended van years ago. I insulated much like you did but added the following. I cut the styro a bit small...1/2 inch +/- Used spray foam to install and seal the edges to metal. Otherwise it will squeak due to the vehicle flexing. Make sure ALL wiring is well secured and protected. Again, flex & vibration will cause chafing and short circuits. Use the weakest possible fuse on all DC circuits. Ain't nothing funny about smellin' smoke at 80+ MPH on the interstate
...and the nearest on-ramp / exit is 50 miles away... One of the best "hiding in plain sight" places I've found.. Hotel parking lot..... Have a paint job / decals for a commercial contracting business. Walk right in and tell the clerk you need to meet an associate in the lounge. Have a couple cold ones...go to van & snooze away.. If ya want to push ya luck ya might get a free continental breakfast. +++A warm place to take a crap & clean up a bit. Ya might even find a lounge lizard to keep ya warm.. Looks good OP.. Keep the fotos coming!! And yes... I lived in a van for awhile.. |
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I have been thinking about possibly doing something like that. But I know I wont have too much issue if I don't. I am only 5'5''. The bed measures 5'9''. Not a lot of wiggle room, but it is longer than the 5.5 pickup bed I usually sleep in on the trips this is aimed for. Had I found an extended van for a reasonable price, I would have put in a full size bed. Maybe in another build in the future. Quoted:
Quoted:
I'm just assuming that unless he's 5'3" he's probably going to put a collapsible platform towards the front of the van and use an air mattress. I'm 6'3" so I kind of make some assumptions. But I know I wont have too much issue if I don't. I am only 5'5''. The bed measures 5'9''. Not a lot of wiggle room, but it is longer than the 5.5 pickup bed I usually sleep in on the trips this is aimed for. Had I found an extended van for a reasonable price, I would have put in a full size bed. Maybe in another build in the future. |
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I really like how the light has turned out in there. I'm impressed with the woodwork.
I have to ask, though...are you going to leave the edges of the cabinet doors square cut like that? I'll loan you a router bit. It's really looking fantastic! Given your insulation, a small propane heater will be more than enough for that space on all but the coldest days, I would think. I'd be more worried about keeping the interior cool enough to sleep in comfortably on warmer nights. Please keep updating the thread! |
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I thought this picture looks neat. I took it last night after a good bit of sanding and Gettin all the lighting in and lit. Plenty of light in there. https://www.AR15.Com/media/mediaFiles/183526/0421192021_jpg-921211.JPG What's your plan for the floor? |
This dude is cool as hell. Hopefully my link works. Bug Out Moto Van Tour | Camp in Van With Motorcycle |
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Quoted: I've been following this thread, looks really good, nice work. I'm a bit jealous. What's your plan for the floor? |
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I really like how the light has turned out in there. I'm impressed with the woodwork. I have to ask, though...are you going to leave the edges of the cabinet doors square cut like that? I'll loan you a router bit. It's really looking fantastic! Given your insulation, a small propane heater will be more than enough for that space on all but the coldest days, I would think. I'd be more worried about keeping the interior cool enough to sleep in comfortably on warmer nights. Please keep updating the thread! I think I will just go with sanding the sharp edges rounded. And go with it. |
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Quoted: I will likely never use it in the winter. But if I need to, a Little propane heater will keep it plenty warm. |
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Quoted: Ventilation looks like it might be a real problem. It doesn't like you have any windows that open in the rear of that van. Unless you're planning on sleeping with doors open, that's not going to work too well. The easiest option might be to try replacing entire doors with those from a passenger van with windows. Hopefully, those will have the style of windows my Astro had. Those pop outward at the bottom so you can have them open, even when it's raining. At camp sites with power, I used to hang a box fan over the driver's side 2nd row window to move more air through the vehicle. It worked brilliantly. If you're really adventurous, you could install one of those low voltage mini attic fan things some RVs have. |
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If you do this get a carbon monoxide checker. I was at the creek the year a father and son were killed by carbon monoxide from a small propane heater in their tent. Be safe we like your builds. Quoted:
Quoted: I will likely never use it in the winter. But if I need to, a Little propane heater will keep it plenty warm. |
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I have always chickened out when it comes to sleeping with a propane heater on, even though it has a Carbon Monoxide detector on it. I'd rather sleep cold than that thing fail and I die. I would think a nice sleeping bag would be plenty warm with all the additional insulation put in the van. Like somebody else said, ventilation/fans/AC would probably be more of my concern. Do those vans run the AC/heat to the back? Or could you add it? It may not be ideal to run the van for heat/AC but would work in a pinch of you think 99% of the time you wont need either. |
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I always love your project threads OP I've always thought these were cool ideas. But being of the 6'1 variety, after insulation and all, it's too narrow to do it like that for me. And having the bed lengthwise down the van kind of kills the layout, imo |
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I dont own a router so I just kinda went with it. I think I will just go with sanding the sharp edges rounded. And go with it. Quoted:
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I really like how the light has turned out in there. I'm impressed with the woodwork. I have to ask, though...are you going to leave the edges of the cabinet doors square cut like that? I'll loan you a router bit. It's really looking fantastic! Given your insulation, a small propane heater will be more than enough for that space on all but the coldest days, I would think. I'd be more worried about keeping the interior cool enough to sleep in comfortably on warmer nights. Please keep updating the thread! I think I will just go with sanding the sharp edges rounded. And go with it. |
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This dude is cool as hell. Hopefully my link works.  https://www.youtube.com/watch?v=XmruWX5hDNoFor a guy posting videos on YouTube, though, he seems oddly inhibited by a desire to stay under the radar. I wanted to see what his vent fans and cameras looked like from the outside but he won't show them because he's trying to "stay stealth", like somebody's gonna recognize the van.  Kinda shooting his YouTube endeavor in the foot.
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Holy moly. I am short about 3 feet on the cedar.
Booooooo. I have to do mucho sanding on the floor. But I think Ittl look good. Attached File |
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Did a little more goofing around today.
Got a 3.5 inch thick full memory foam roll and a 1.5 inch topper and cut and wrapped it up into a mattress. Finished the bed frame and did some poly filling and felt covering on one of the pillars. Covered nicely. Attached File In the process of covering and trimming. Attached File Final trim work. Attached File Attached File Attached File Attached File |
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Is there a plan for the door? I imagine since it's a sliding door you can't do much but it sure looks out of place. Surprisingly there is a ton of room for materials. I could tongue and groove it like the rest of the van too if I wanted. |
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Quoted: Oh yeah. There is a plan for it. Surprisingly there is a ton of room for materials. I could tongue and groove it like the rest of the van too if I wanted. |