WORK AND MATERIAL PLANNING

More time to plan = less time to build.

1. VAN PREPARATION

1- Interior removal.

2- Seal fasteners of exterior black plastic cladding.

3- Apply rustproofing to lower floor areas.

4- Apply rustproofing under the van.

RESOURCES:

MATERIAL:

  • BLABLA

TOOLS:

  • BLABLA

2. TIRES UPGRADE

The Transit stock tires (Hankook 235/65/R16) are quite small in diameter (28″) and the threads are just ok. Larger diameter and more aggressive threads will help for ground clearance and improve traction for off-road and winter conditions. The Cooper Discover AT-3 and the BF Goodrich KO2 seems the popular options; we’ve chosen the BF Goodrich KO2 LT225/75/R16E for the reasons below:

RESOURCES:

SELECTION NOTES (all based on reading the forum mentioned in the above resources):

  • Choose “LT” tires for “Light Truck”
  • Choose “E” rating for stiff sidewall and sufficient load rating (“E” = 10 plies)
  • The BF Goodrich KO2 are approved winter tires (there is a little snowflake on it)
  • Tire Diameter
    • Stock factory tires diameter: 28″ (235/65/R16)
    • Best compromise and enough clearance for chains: 29.2″ (LT225/75/R16E)
    • Largest diameter without rubbing, no clearance for chains: 30.4″ (LT245/75/R16E)
  • Tire Width
    • Too wide and performance in snow will decrease. For this reason we rejected the LT255/70R16E (30″ diameter, 10.2″ width) and choose LT225/75/R16E instead (29.2″ diameter, 8.8″ width).

3. FAN INSTALLATION

 

RESOURCES:

MATERIAL:

  • Maxxair Fan 6200K Black, 215$ US on Amazon.com
  • Fan Adapter for Ford Transit (outside & inside), 96$ US Impact3D
  • Dicor 551 LSG-1 Lap Sealant, 10$ on Amazon.com
  • Putty Tape, 13$ on Amazon.com
  • 3M Marine 4200 adhesive/sealant, 23$ on Amazon.com
  • Paint for sheet metal touch-up (for trimmed edges)
  • Zinc coated wood screws (#10 7/8″ and #10 3/4″) and washers (#10)
  • Painter’s tape
  • Duct Tape
  • Acetone
  • Isopropyl Alcohol

TOOLS:

  • Jigsaw

 

4. SOLAR PANEL INSTALLATION

 

RESOURCES:

MATERIAL:

  • Grape Solar 160W Solar Panels 12V (quantity 2), Amazon.com 229$ US (each)
  • 3M VHB Tape (4991), 1″ width, 5 yards length, Amazon.com 34$ US
  • Renogy Z mountain brackets, Amazon.com 14$
  • MC-4 Multibranch Connector pair, Amazon.com 11$ US (to connect panels in parallel)
  • Cable gland 90° 3/8″, Amazon.com 13$
  • 30′ Extension Cable with MC-4 Connectors 8AWG, Amazon.com 32$ US (cut in half to get 2 times 15 feet length)
  • Dicor 551 LSG-1 Lap Sealant, Amazon.com 10$

TOOLS:

  • Drill

 

5. SWIVEL SEATS INSTALLATION

 

RESOURCES:

MATERIAL:

TOOLS:

  • Nothing fancy

 

6. AWNING INSTALLATION

RESOURCES:

  • FordTransitUSAforum post

MATERIAL:

TOOLS:

  • TBD

 

7. THERMAL AND SOUND INSULATION

  1. Cut piece Thinsulate with scissors.
  2. Apply 3M 90 Spray Adhesive to both van sheet wall & Thinsulate.
  3. Let the 3M adhesive tack for 45-60 seconds.
  4. Press Thinsulate against the van wall.

RESOURCES:

MATERIAL:

TOOLS:

  • Nop

 

8. FLOOR INSTALLATION

  1. Fill lower portions of the van floor with ½” thick polystyrene C-200 foam board. Bond the foam to the van floor with 3M 4000UV (3M 4000UV is recommended for plastic and has lower strength then 4200. We don’t need very high bonding, we just want to prevent squeaking. See article on sealant and caulking properties here. See 3M 4000UV datasheet here)
  2. Apply 3M 4000UV to bond the ½” fillers to 1″ foam board.
  3. Apply 1″ thick polystyrene C-300 foam board all over floor.
  4. Use uniform weight to bond foam boards together properly.
  5. Apply Mass Loaded Vinyl (MLV) sheet (no bonding)
  6. Apply ½” thick plywood all over floor (no bonding)
  7. Apply Vinyl sheet flooring (no bonding)
  8. Use brackets to retain floor assembly (brackets could be attached via D-ring bolt holes or Plusnut)
  9. Seal large gaps around installed floor & van wall with Great Stuff (gaps & cracks)
  10. Seal edges of vinyl sheet with van wall with GE Silicone ii (Silicone is highly flexible and will stay flexible at low temperatures)

 

RESOURCES:

MATERIAL:

TOOLS:

  • Circular Saw
  • Jigsaw
  • Caulking Gun

 

9. BED INSTALLATION

We’re going shopping! This is a draft for BOM purpose (not all structural details shown):

Vertical Legs

  • 4″ x 1″ (QTY 6 = 24″ wide required)

Horizontal Structural Slats

  • 4″ x 5/8″ (QTY 3 = 12″ required)

Structural Slats Reinforcement

  • 2″ x 1/2″ (QTY 3 = 6″ required)

Bed Frame Contour

  • 2″ x 1/2″ (QTY 2 = 4″ required)
  • 4″ x 1/2″ (QTY 2 = 8″ required)

RESOURCES:

 

MATERIAL:

RUSSIAN BIRCH

1″

 

 

TOOLS:

  • BLABLA

10. GALLEYS & DRAWERS

Build & install galleys. Refrigerator, sink & pump, kitchen range.

Build & install clothes drawers. Ventilation?

RESOURCES:

  • BLABLA

MATERIAL:

TOOLS:

  • BLABLA

 

11. ELECTRICAL SYSTEM

Plug & install electrical system.

RESOURCES:

MATERIAL:

  • Charge Controller: Bogart SC-2030 30A PWM, 161$ CAD on wegosolar.com
  • Temperature Sensor: Bogart TS-2, 17,50$ CAD on wegosolar.com
  • Battery monitor: Bogart TM-2030-RV with 500mA shunt, 246$ CAD on wegosolar.com
  • AGM battery: Rolls Surette S12-2303AGM (210Ah), 598$ CAD at thesolarsupermarket.com
  • Battery-to-battery charger: Sterling-Power, 278$ US
  • Fuse Box: Blue Sea 5026 ST (12 circuits), 39$ US on Amazon.com
  • ON/OFF Master Switch: Blue Sea 6006, 28$ US on Amazon.com
  • 2016-08 Shopping list:
    • AWG 2 RED: 4 feet
    • AWG 2 BLACK: 4 feet
    • AWG 0 RED: 12 feet
    • AWG 0 BLACK: 12 feet
    • 2x 9mm (3/8″) AWG 4 ring terminal (house battery)
    • 2x 3/8″ AWG 4 ring terminal (shunt)
    • 8x M10 (3/8″) ring terminal (switches)
      • 4x AWG 8
      • 2x AWG 4
      • (2x AWG 2)
    • 10x 1/4″ ring terminal (bus bar)
      • 6x AWG 8
      • 2x AWG 4
      • (2x AWG 2)
    • 12x #8 ring terminal (fuse box)
      • 4x AWG 14
      • 6x AWG 12
      • 2x AWG 10
    • 2x #10 AWG 8 ring terminal (fuse box)
    • 6x #10 AWG 8 ring terminal (breakers)
    • Kit of heat shrink butt wire crimp connectors
    • ATO-ATC Fuses (kit)

TOOLS:

  • BLABLA

 

12. TOILET & COUCH

Build & install.

RESOURCES:

MATERIAL:

  • BLABLA

TOOLS:

  • BLABLA

 

13. CARGO STORAGE INSTALLATION

Bike & cargo sliders. Build & install other storage (sport equipment, shower, etc). Finish walls.

RESOURCES:

  • BLABLA

MATERIAL:

  • Full-Extension slides, 36″, 250 lbs capacity. 38$ US. Tchweb.com
  • Ball-bearings full-extensions slides, 48″, 500 lbs capacity. 245$ US. Amazon.com
  • Full-extensions slides, 48″, 400 lbs capacity. 215$ CDN. LeeValley.com

TOOLS:

  • BLABLA

 

14. KITCHEN & BEDROOM STORAGE

Build & install storage.

RESOURCES:

  • BLABLA

MATERIAL:

TOOLS:

  • BLABLA

 

15. GAS HEATER INSTALLATION

The Webasto will be installed under the passenger seat.

  1. From an aluminium sheet, trim and drill the Webasto intallation template in order to provide a flat surface (required per manufacturer instructions).
  2. Transfer the template holes to the van floor (air intake & exhaust, fuel line, 4 bolts).
  3. Apply primer, paint & clearcoat the aluminium template & to the van floor. Put anti-erosion tape on surface common with the van.
  4. Fit the Webasto unit in place. Screw 4 bolts temporary (the final tightening & sealing will be performed at the final step when everything looks fine!)
  5. Install the air intake & exhaust. Secure using collars.
  6. Route the air intake & exhaust using fittings.
    • Pipes must be falling away from heater (to prevent condensation buildup)
    • Pipes must not face direction of travel
    • Pipes end must be vertical +-10 degrees.
  7. Route the fuel line & fuel pump electrical cable toward the van gas tank & above the van muffler heat shield. The fuel line will be routed within an automotive “rubber” (or alu?) fuel line to protect it from damage.
  8. Lower the van fuel tank and install the Ford 90° auxiliary fuel port.
  9. Install the Webasto fuel pump close to the van fuel tank port using the anti-vibration fitting.
  10. Connect all the fuel line & electrical cable (Webasto unit to fuel pump, fuel pump to van fuel tank).
  11. Raise the van fuel tank.
  12. Install & connect the Smart Controller.
  13. Connect the Webasto unit to 12V power.
  14. Go put some gas in the van.
  15. Fire up the heater, fingers crossed.
  16. Success? continue…
  17. Make a hole in the seat base and install the hot air exhaust.
  18. Loosen the Webasto unit and reinstall permanently using GE Silicone II to seal from water.
  19. DONE.

RESOURCES:

MATERIAL:

  • 90° auxiliary fuel port CK4Z-9B210-A
  • Webasto & Installation kit MellorOnline
  • Webasto Smart 7 days timer MollorOnline
  • Some automotive fuel line (to protect Webasto fuel line from damage)

TOOLS:

  • Nothing funky

 

16. FINISH WALLS

 

RESOURCES:

MATERIAL:

TOOLS:

  • BLABLA

 

17. SHOWER

BLABLA

RESOURCES:

MATERIAL:

  • Water Heater Pan (specs)

TOOLS:

  • BLABLA
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