2000 Chevy Express project

[dvdchris]

How about Nylox nuts on those genny mounting bolts???

Ok; I picked up a couple and they are hard to put on. Have to get my brother to help me with that.

I came up with this simple flap to conceal the ugly where the conduit emerges from the van floor. I will secure it with a simple tiny bungee hooked to loops.

Getting ready to fit the passenger wall panel.

Wall panel final cut.

Outlet hole cut.

It fits pretty well. Will need an outlet box extension to finish out the outlet cover...

 

[dvdchris]

Okay...really?

Not liking the looks of the junction box open to the weather with a mess of wires and tape coming out of it, (wires that carry AC power from the generator!) I'm replacing the wire nuts with waterproof ones and replacing the box too, which will have a cap screwed shut on it.

Unbelievably, I lost the package of new wire nuts and will have to finish up tomorrow after getting another new package.

 

[dvdchris]

Finished buttoning down wall and outlet trim

 

[dvdchris]

Got my carpet padding laid down.
This will probably be it for today since it looks like rain is rolling in...

 

[Bela's Mom]

That is really looking good! Thanks for sharing the pics!

 

[dvdchris]

Had jobs all weekend and it has been pouring rain today and yesterday. Started working on a box for my batteries.

Turning out ok so far for a quick and dirty plywood box. Nailed, screwed, and glued.

Also, the Walmart near here has a pretty good selection of vans and RVs that spend the night.

 

[dvdchris]

Was very nice today after all the storms. Making a lid for my battery box and the tie downs for the straps got attached.

Started cutting out a subfloor section too. This is 11/32 plywood sheathing from Home Depot $15

Nephew supervising measurements

Looks good

 

[dvdchris]

Laying out the next piece

All pieces cut and laid out

 

[WheelEstate USA]

Lookin' good. Nice work.

 

[dvdchris]

Thank you.
Got all the pieces screwed in place today, drilled access holes for the generator mounting bolts, put trim back together by the driver door, and made rope handles for my box

 

[PastTense]

Any tricks to measuring and cutting that subfloor section? When I try to cut pieces like that they never fit.

 

[dvdchris]

Well, if I was smart, I would have used the cut carpet padding and laid it out on the plywood as a template...as it was I had already taped it down and didn't want to pull it up, although I did use one piece, a wheel well curve, as a guide. You could get some heavy paper from the hardware store and use that to make a template.
I used the removable floor trim from the rear and drew a pencil outline directly on the plywood and cut it out with a jigsaw. The rest, width, corners, etc, were just careful measurements. You want to err on the side of leaving the piece larger because once you cut the wood, you can't make the piece any bigger. Also you want to use as many of the straight edges as possible when it comes to fitting them together, not edges you cut yourself. All seams where boards meet were factory cuts, leaving my cuts for the outer edges.
There were a few fit and cut moments; and I didn't get the edge by the side door as straight as I should have, but it will be hidden by the laminate floor planks.

 

[Bdog1]

How about little detail on that generator you mentioned. That's on my "wish" list.

 

[dvdchris]

The generator is an Onan 2800 Microlite tied to the gas tank with a remote panel start/kill switch, a typical RV install. It is just 3 years old, as they replaced it in June 2011 for a cost of $2800 at Camping World.

 

[Bdog1]

Thx.... Nice set-up.

 

[dvdchris]

Going to try to dress up this power station with some leftover plywood pieces. It is currently a half ass black plywood piece that doesn't have any kind of finished appearance. I also want a larger back board to allow for mounting my inverter and solar charge controller.

I have two sanded pieces I don't want to waste. I'm strapping them together, edge banding them and staining to make one piece. I am not a carpenter, and this is my first attempt at edge banding or staining anything since 7th grade wood shop.

 

[Bdog1]

Looks like you paid more attention in seventh grade than me! Lol

 

[dvdchris]

 

[dvdchris]

Started cutting pieces for the wheel well boxes today. They will provide the base for the bed.
Used the flooring planks to start installing one 'straight' in relation to front and back.
Also dropped off driver seat at an upholstery shop to get it redone.
It threatened to rain today, so I closed everything up until it passed. Didn't end up getting much done.

 

[Bdog1]

My platform has 14" clearance for storage, this resulted in a little hidden storage above the wheel wells that was boxed in. I made a lift out panel for access. Here's a pic where you can kinda see it. Sorta!

The drivers side is used by the rear AC on my van though.

My woodworking skills are primitive at best, I built the platform to free stand without using the walls for support to try control squeaks.

My desk area ties in top and bottom and sounds like a school bus going over bumps. Need to make improvements.