Ford Transit build out

[Clean1]

Hello,
I thought I would post up my build here for the chance it may help someone out in the future, I know I poured through these posts and other "van" forums and found them invaluable in helping me build out my van.

The mission is to build out our Vome for exploring Mexico and Central America. We leave around the end of December or the beginning of the year. I apologize for the link for pictures but I can not seem to figure out how to load them from this site I keep getting this error DSC_0004.JPG: Upload of file failed. If someone wants to help me out I would be grateful. I want to thank everyone who has gone down this road before me that has posted info and pics showing the way on outfitting a vehicle for travel.

The team
The Vome
https://goo.gl/photos/vcvuubkAfYRXgnWi9
The big boss
https://goo.gl/photos/XAyxHqQ4LQGDhoNy7
Stinker One
https://goo.gl/photos/Gxg4EBWYGZXq4aEDA
Stinker Two
https://goo.gl/photos/7r33sFBjbxLNZE94A
The Team leader
https://goo.gl/photos/n8eoTYTdJXe6SFh48

 

[Clean1]

Here's what we started with,
https://goo.gl/photos/912ayP5vwi6U1Po19
https://goo.gl/photos/weK4kUNtrx17w3Yp7
We started playing around with cardboard mock-ups to get a feel for where to place things, like the refrigerator, bed, couch etc.
https://goo.gl/photos/U9eocLVf6cfZSQTt5
https://goo.gl/photos/c4hVkwtNq4Nnm5Mj7
So we stripped out the stock van panels and vinyl floor and started insulating. We used Thinsulate and refletix
Thinsulate was stuffed everywhere we could
https://goo.gl/photos/5171XwukxnsdJXGq6
https://goo.gl/photos/J4GroVe1m4amC5nH6
https://goo.gl/photos/mfNMGjYRU3ZN1JVx6
https://goo.gl/photos/pzwDLq859s8KY8io7
We put in behind the doors and above the headliner as well
https://goo.gl/photos/u8U3n56p8TLJic4y5
https://goo.gl/photos/GcgCiaWjzM1e8y5z8

 

[bknudtsen]

Best to use a site like photobucket so that you can use the

 

[Clean1]

Insulation behind the doors and headliner
https://goo.gl/photos/pFkzeCNQ9erpv83m9
https://goo.gl/photos/HX8HWSL147DeE7P46
Insulated and the vinyl floor back in. It made a big difference in road noise coming in as well as heat radiating in from outside. (I started this this build in August in Scottsdale AZ)
Now to tackle insulating above the the headliner. Headliner out.
https://goo.gl/photos/uYSz2XvhGttaE6WX6
Lots of cavity area for insulation
https://goo.gl/photos/burQjVY7FMFexxTy9
Insulation in above the headliner.
https://goo.gl/photos/qVKNc8Jp8Wygews18
Now to put in back in with no left over parts
https://goo.gl/photos/9VPW8bLrEitWNphdA
Time to put dynamat on the floor for sound deadening
https://goo.gl/photos/jGThxj4tFoy1azQf9
https://goo.gl/photos/WThHf89ncEqukGdq6

 

[Clean1]

4x4 options

So there are a few options for converting the Transit to 4x4 and unfortunately U-Joint isn't one of them. I sent Chris a couple e-mails trying to talk him into converting mine but he wasn't interested. Chris seems like a great guy and I have really enjoyed the builds he has posted on this site the vans he builds are impressive. So QuadVan it is. I have been keeping in touch with Jon at QuadVan and it looks like he isn't to far out to get one done. If I'm lucky I will have mine done by the end of the year, if I'm not lucky than early next year. I believe stock tire size is limited to about one size bigger 245/75/16. I'm not sure what the tire size will be after the conversion a 33 would be ideal but not sure if that is going to be possible. The wheel wells have body seams in them that would need to be cut and pounded over to get more clearance but I'm not sure if the amount of work would be worth the gain in tire size.

On a different note I just found out my Aluminess rack and bumper are ready and I'll be making the trip there on Monday to get them installed. Booya!!

 

[Clean1]

Back to the build, after the sound deadening I received a delivery from China via Kelly in Utah from Electric Car Parts Company. My house batteries had arrived


Time for a mock up of the mechanical well with the hot water heater, water pump, water tank and batteries

 

[Clean1]

The refrigerator came so I was able to add that to the mock up as well

Started working on the subfloor with my vinyl floor as a template

My helper laying down on the job

Subfloor roughed in ready for the mechanical well

Mechanical well framing started

Battery box in mechanical well

 

[Clean1]

Mechanical well in the van
View attachment 307401
Time for a real test of my fortitude and gumption, cutting a big hole in the side of my van. I had been dreading this but knew that it would make a big difference in opening up the van.
Test fit and yes it fits, at this point I'm crapping my pants.
View attachment 307404
Drilling pilot holes to connect the holes when I use the jig saw
View attachment 307405
Pilot holes drilled
View attachment 307407
Time to start connecting the holes with the jig saw

A new view

Time for the 3M window cleaner, 3M primer and 3M caulk

 

[mezmochill]

Nice.

How many amp/hours in that battery pack ? What type of safety mechanisms are involved with a lithium bank like that?

Good luck, going to be sweet!

 

[Clean1]

Time to stick it on and see what's really going on....and I screwed up, as I set the window on the bottom of the lip and started pushing up, the window slipped off the lip and I got caulk
all over where it wasn't supposed to be. My wife was kind enough to take pictures of it for me.

Now for my high tech pressure rigging device to keep the window firmly in place while I figure out how the hell I'm going to get all the black caulk off the side of my van.

A little WD-40 and elbow grease saves the day

Window done and looking good

 

[Clean1]

Mezmo, it is a 1000 amp hour battery pack, basically 4 rows of 10 batteries hooked up in series and then the 4 rows are hooked in parallel. It's LifePo4 not lithium. Much safer and no issues like the previous lithium batteries.
Thanks for the kind words.

 

[michaeldorian]

Awesome build. John is a hard guy to get a hold of at QuadVan. Are you doing the 4in lift he offers? Do you know if that is going to give you enough clearance for what you want?

 

[Clean1]

MD,
Thanks! I'm not sure if John has changed his ways or what but the last 4 times I've called he has either picked up or has been available to talk. Yes I am going to go with the 4" lift and I'd be happy
with an extra 1-2 inches (insert pun here) of ground clearance. The tire on there now is roughly a 28" so a 32" tire would get me where I'd like to be. John still wasn't sure exactly what size tire was going to fit for the 4" lift.

 

[Clean1]

Back to the floor, broke it into 3 section and framed it with 80/20

Beefing up the mechanical well area for the weight that will be on top of it

The big boss helping out, the drill press scared the crap out of here but she did it anyways like a boss!

The Mechanical well in and equipment as well.

Hot water for shower=happy wife=happy life

Had a stereo system, back up camera, perko/security lock out installed and the old air conditioner

 

[Clean1]

On with the build, I cut up some 3/4 oak plywood for the 12" x 36" Adventure Trailer drawers and Drifta chuck box to sit on

Looks like they will fit with room to spare

I'm using 1x's to keep the plywood deck in place, it wedges up against the 80/20 for a snug fit.

Plywood covered and 80/20 to keep the A/T boxes and chuck box in place


Got the rear plywood covered and shower box roughed in.