HazVan - 2002 E-350 SuperDuty 7.3l PSD

[turbodiesel]

Last month bought a used Hazmat van from a local fire department. High mileage but was cheap. Been cutting it to pieces in prep for assembly as an off-road camper.

Specs:

• Make/Model: Ford 2002 E-350 Super Duty
• Engine: 7.3l PSD 260K miles
• Drive: 2WD
• Color: White & Red
• Exterior: Generator storage, 10 gallon gas tank, flood lights, emergency amber bar, shower and eye wash station
• Interior: Swivel passenger seat, steel cage, aluminum storage, water tank, and fold out table

General plans:
Create a camper for climbing and back country expeditions.

Progress to date:

• Removed most of the cargo storage
• Removed gas tank
• Removed cargo headliner
• Removed extraneous wiring (no longer hooked up)
• Removed failed seals in roof
• Replaced stereo headunit
• Sound damped front doors
• Replaced ignition switch
• Replaced multi-function switch (signals, wipers, etc)
• Replaced speakers
• Replaced interior lights with LEDs
• Replaced interior cargo door lights with LEDs
• Repaired roof with new seals or patched where needed
• Rewired entire cargo area for running off of a house battery (GoZero 1400)
• Replaced side flood lights with LEDs
• Rewired external side flood lights to run off of house battery
• Replaced rear flood lights with LEDs
• Insulated sides
• Installed van roof rack
• Installed light bar in front (vehicle battery)

Todo List:

• Oil change
• Transmission Oil change
• Fix window wipers - tracking down an electrical issue with help of the workshop manual
• Fix power locks - possibly VSM, still tracking down with help of the workshop manual
• Insulate roof (Foam panel insulation with spray foam)
• Paint interior roof black
• Paint interior white
• Stain wood slats with light stain
• Seal slats with poly
• Install wood slats
• Build & install cabinets (design incomplete)
• Build & install couch/bed (design complete)
• Aluminess Tire Rack (ordered)

Wish List:

• 4x4 Conversion (UJOR)
• Pop-top (Colorado Camper)
• Roof Rack (Aluminess)
• Propane heater (Suburban)
• Propane water heater (shower & dishes)
• Repaint red to black Line-x
• Powder coat bumpers to black

Instagram

 

[turbodiesel]

More pictures of the lights

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[Bikersmurf]

Looks good, looking forward to seeing what you do with it.

 

[turbodiesel]

Looks good, looking forward to seeing what you do with it.

Thanks! Love following your build as well! Which heater did you install? Noticed it was electric.

 

[Bikersmurf]

The heater is a Dimplex Model # RKHA20D31W. It's a kick space heater that can be wired for 120-240v and 450w-1800w. I've got it wired to 120v and 450w right now. I plan to hook up a thermostat eventually, but for now it's on a timer set to run 5am-8am. If it gets colder I'll adjust it to run longer. There currently is no heat in the box so it's nicer for the kids in the back to keep the chill off it sometimes. I have plugged it into the inverter when it has been cooler to keep it slightly warmer in the back when leaving kids in the vehicle in winter while popping into stores. I've also picked up a 12v electric blanket from Walmart which will also be helpful.

It rarely gets below freezing here, so the insulated box stays warm for quite a while. I've got styrofoam insulation which I'm going to spray glue the scrap curtain leftover from shortening a curtain for the walk through area. It'll be mostly for privacy, but insulating the 3 box windows will keep it cooler in the summer and warmer in the winter.

 

[turbodiesel]

Insulated the roof with panel insulation and spray foam to fill in some of the gaps. I'm not living in it, so my insulation job isn't a crazy R value. Added reflectix to smooth out the roof look and add a little R value on the ridges. Height is at a premium, so nothing more than a 1/4" air gap. The finished roof will be thin wood slats with a light stain and poly. Hopefully start that tomorrow.

 

[turbodiesel]

The heater is a Dimplex Model # RKHA20D31W. [...]. I've also picked up a 12v electric blanket from Walmart which will also be helpful.
[...] It'll be mostly for privacy, but insulating the 3 box windows will keep it cooler in the summer and warmer in the winter.

I'll have to check that out. Leaning towards dropping the tank and connecting a small diesel heater, but that's going to be a pain.

12v electric blanket, now that's a great idea. Wife will like that a lot. I didn't realize they even made those.

 

[ujoint]

Good bones ready for a transformation!

 

[Bikersmurf]

I hadn't seen them before either. Some are pricey, but these were only $30 CDN. I believe my wife will like it also... can't go too wrong with a fleece blanket that also has three levels of warmth.

Usually it’s not too hard to stay warm at night with the right combination of blankets. The challenge is usually getting warm enough. A 5amp draw for a few hours overnight could be a good way to be cozy.

 

[turbodiesel]

Good bones ready for a transformation!

I have a draft in my email ready to send your way. No time like the present to start discussions on what I need to start sourcing.

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[turbodiesel]

I hadn't seen them before either. Some are pricey, but these were only $30 CDN. I believe my wife will like it also... can't go too wrong with a fleece blanket that also has three levels of warmth.

Usually it’s not too hard to stay warm at night with the right combination of blankets. The challenge is usually getting warm enough. A 5amp draw for a few hours overnight could be a good way to be cozy.

Is think so. Just enough to keep the chill off on the early morning.

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[turbodiesel]

Building the bed/couch. Excuse the crappy pictures, I'll get better ones in the morning.

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[turbodiesel]

A few pictures in the daylight

2002 Ford E350 7.3l PSD

 

[turbodiesel]

Mocked up the cabinet. Built the supports for the top aluminum cabinet out of aluminum as well. The wood is just there to hold it in place for installation. I'll bolt the aluminum up and remove the wood. Base is out of wood to match the bed/couch.

2002 Ford E350 7.3l PSD

 

[Bikersmurf]

Are you going to cover &/or pad the aluminum so you it won’t be so hard/cold?