2001 E-350 extended WB build

[dr_nelson]

Looks like a pretty good fix.  Best possible short of welding.

Thanks, time will tell how good of a job I did.
I was contemplating to get a welder and teach myself to weld for a battery hold-thingy but I wouldn't trust myself that it held in place. So, the batteries will be "inside" in a box.

 

[dr_nelson]

Three camping mats and several blades later:
(darn, those things get dull so quickly)
[img=537x403]http://i58.photobucket.com/albums/g...C9C1938-1355-458A-B55F-925116BEA2E0.jpg[/img]

I am glad this part is over.
I will follow Bob's advice and not put any further insulation (e.g. polyiso) on the floor. With my medium height high-top roof, every inch counts. I'll probably loose a solid full inch when insulating the roof.

One step at a time...

 

[highdesertranger]

looking good. that patch on the crack should work. highdesertranger

 

[dr_nelson]

Moving up in the world... started to put in the floor. I was very surprised it fitted with one cut only - thanks to a tedious  template.
My vinyl floor should arrive next week.
[img=678x508]http://i58.photobucket.com/albums/g...6F7B958-37DB-4AA0-865B-868AE6B7AAB0.jpg[/img]

 

[AbuelaLoca]

Did you link to the camping pad earlier? I might like to go that route myself...

 

[dr_nelson]

Did you link to the camping pad earlier? I might like to go that route myself...

I didn't link it. For the floor, I just took three cheap camping mats from Walmart. I will check when I get home what exact brand it was.

I found this site that 'shoots the shit around' about R-values of different camping mats (according to the site, this list was updated in 2017).
I was only looking at the "closed cell" ones and will use them where the contour of the roof and walls would make it a little difficult to fit the rigid polyiso (and then put polyiso over it).
Disclaimer: I am not sure if you can take those R-values for granted, but it is good enough for me.

Btw, I think it was HDR, but there are several mentions about the ensolite closed cell foam...

 

[dr_nelson]

[font=Tahoma,Verdana,Arial,sans-serif]The camping mats I used for the floor are from Ozark Trail. $6.97 from Walmart.[/font]
[img=469x351]http://i58.photobucket.com/albums/g...45DD27B-D5E2-472D-8984-C28211451E49.jpg[/img]

 

[dr_nelson]

My solar panels have arrived. 2 x 180W Grape Solar from home depot, each for $199.-
Their special must have ended, they are now back at $258.-

The cardboard boxes didn't show any dents, but when I opened the box, both of them had dents in the aluminum frame. One small, the other pretty significant. This just tells me that these panels left the factory like this... How can this pass quality assurance?
I guess the special price included dents... bummer.
The cells themselves look fine.

[img=573x429]http://i58.photobucket.com/albums/g...6B2A51A-26FF-4CEB-8F1B-DCE7CEAD173B.jpg[/img]

[img=576x432]http://i58.photobucket.com/albums/g...0EF372E-B0D2-4B93-801B-6AFEF7A1AA40.jpg[/img]

I am not that much of a cosmetic/aesthetic guy. I am more focused on a thing to work, than to look nice.
But, do you guys think I should return the one with the big dent?

I haven't figured out yet how to "test" a solar panel without a battery and without a charge controller.


PS: Man... I immediately had to think of Rolling Earth-Ship... youtube video here. Can't remember his forum nickname. And his panel looked much worse than mine, but it seemed to be working fine for him.

 

[highdesertranger]

yep that was me with the Ensolite. great stuff. you can take a 3/4 inch pad, lay it on snow and sleep on it without feeling the cold come through. highdesertranger

 

[John61CT]

The cardboard boxes didn't show any dents, but when I opened the box, both of them had dents in the aluminum frame. One small, the other pretty significant. This just tells me that these panels left the factory like this... How can this pass quality assurance?
I guess the special price included dents... bummer.

Yep you got seconds, they're counting on you not bothering doing the return.

I would thoroughly test functionality throughout the warranty period, may not just be cosmetic

 

[dr_nelson]

And there goes another weekend and I didn't accomplish much.



I tested the solar panels.
Test Result: 49.9 V (Voc), 9.80 A (Isc)
Spec says 24.06 V (Voc), 9.77 A (Isc)
[img=334x329]http://i58.photobucket.com/albums/g...81E59B5-6E00-47AA-A1DD-9FB94FF876CA.jpg[/img]
Since the numbers are "above" the specs, I assume the panels are performing "OK".



Found this stuff at Home Depot. A Corvette forum used it for sound deadening, so I used it here and there. It is much cheaper than Rattletrap but also not as sound-deadly. Still, good enough for me. The doors don't sound like a metal-sheet drum anymore.
[img=410x308]http://i58.photobucket.com/albums/g...1FEF36F-CD6C-441E-9728-2184790BC6EB.jpg[/img]

[img=410x306]http://i58.photobucket.com/albums/g...A998A8E-FB6C-4B2F-B364-58FED466E86D.jpg[/img]


Finished adjusting the plywood for the floor:
[img=414x414]http://i58.photobucket.com/albums/g...B32C588-287C-4AA9-B525-22B5444269D0.jpg[/img]

[img=408x408]http://i58.photobucket.com/albums/g...568115E-4BFD-4364-BE85-F442ACCF9A7E.jpg[/img]



Since I have 100 holes in the floor from e-tracks and whatnot, I made use of those existing holes to secure my floor to the van. T-nuts came in handy, since I didn't need anyone to hold something inside the van while I was screwing from underneath the van:
[img=403x302]http://i58.photobucket.com/albums/g...561BE81-1BDF-4BDC-8CA6-5B5FB897ECFF.jpg[/img]

[img=408x408]http://i58.photobucket.com/albums/g...DFD35DD-27A6-4FC6-8B8E-C8F8F26AB4BA.jpg[/img]
Some of them, I'll use to secure "furniture" to it. Others, I've just cut them flush, so that the vinyl-floor can cover them nicely.


I noticed that the plywood at the big boxes are really hit or miss. Some are of awful quality. Where can one buy some quality plywood, or what do I have to google? Carpentry shop?

Being from Europe, the imperial system drives me nuts when it comes to buying bolts/screws, nuts, and washers. And on top of that , the screws and bolts are all over the place. People seem to just throw stuff back no matter the size. Half of the hardware is not even what the label says it is.


PS: I am tediously re-sizing the pictures knowing some folks have limited data.

 

[John61CT]

That way-high voltage is odd, be aware may cause problems with a controller, many will take over-current OK, but over voltage fries it.

Maybe have a pro look at it?

 

[Gunny]

Very impressive work. Well done.

Rob

 

[dr_nelson]

That way-high voltage is odd, be aware may cause problems with a controller, many will take over-current OK, but over voltage fries it.
Maybe have a pro look at it?

OK thanks John61CT, that's good to know. I found it strange, too, that voltage is so high. But then, those numbers mean nothing to me, i.e. I don't know anything about it.
The panels are 180W each, Grape Solar, and right now I am thinking of returning them and getting 4 x 100W Renogy.

 

[John61CT]

OK thanks John61CT, that's good to know. I found it strange, too, that voltage is so high. But then, those numbers mean nothing to me, i.e. I don't know anything about it.

Why I say have a local shop check them out, could be your mistake, maybe they're fine.

 

[dr_nelson]

Thank you John61CT, I returned the two 180W Grape Solar panels.
My original intent was to have those two and add a 100W panel. But since this is not feasible, and since Renogy had a sale today, I am going with 4 x 100W Renogy panels.

 

[caretaker]

Quick tip about utility knife blades,,,a sheet of 660 grit or finer wet/dry sand paper works really good for dressing a utility knife blade,,,,will help you get thru most jobs

 

[dr_nelson]

Had a community yard sale today. The rest went to Godwill. Good thing the van is still empty


Started wall insulation with 1/2 inch polyiso boards. 1/2 inch is nice, as it sort of fits the curves of the van.
It will be a minimum of 1 inch, other spots even 2 inches. Ford has quite some cavity by the wheel wells. My whole arm fits in there.
The shiny side is facing outward to reflect heat "away".

[img=571x428]http://i58.photobucket.com/albums/g...EE423DB-D3EA-4C58-80C0-B9361F8DF4E7.jpg[/img]

[img=572x430]http://i58.photobucket.com/albums/g...AAAE49E-4261-4ADE-9202-3F5B8ED87D50.jpg[/img]


On top of it I will put a layer of Reflectix, as there will be a gap. I am hoping that this will keep the heat inside in the winter.
And on top of the Reflectix, I'll put something like Luan.

The driver's side window I'll probably cover.
The 3M 90 adhesive spray is awesome. Used it back in Switzerland to insulate the roof of my VW Bus, and the insulation was rock-solid.

Wear gloves...

 

[mikEXpat]

Great thread. I'm looking at getting a similar set up as you and doing a very similar build. So, I'm subscribed and following. Good work so far. Looks like everything is going well.

You wired your solar panels in series. As long as you have a 40a MPPT controller and (ideally) 400ah of battery power, you're fine.

Happy building,
Mike

 

[dr_nelson]

It's been a while. My van was basically just sitting there for a month and it has been raining a lot in humid SC and water had been dripping onto my plywood floor. There were two spots, one from the window and one from the rear door seal.

Just wanted to share that just within a month dark spots started to spread (which I believe is mold):
[img=427x318]http://i58.photobucket.com/albums/g245/dr_nelson/Van Build/IMG_0684.jpg[/img]

[img=427x320]http://i58.photobucket.com/albums/g245/dr_nelson/Van Build/IMG_0685.jpg[/img]

Took the entire floor out and am painting both/all sides (top, bottom, and edges) with Mold Killing Primer:
[img=427x320]http://i58.photobucket.com/albums/g245/dr_nelson/Van Build/IMG_0686.jpg[/img]