2014 Chevy Express 2500 Van Build: Luisafernandes

[Luisafernandes]

Friday got a few trim pieces up, which serve two purposes; 1- it divides the clothing cabinet from the pantry, and the pantry from the desk/table, and 2- it makes for a better finish, I think.
Here's some pics:

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Today, Saturday I tacked two things: the over bed cabinets on the opposite side, and the roof vent.
For the cabinet, since I left some pieces drying from last weekend, all I had to do was installed them. I still had to trim the backside (the side that goes against the wall) of the shelf so that I could raise it up about 3/4 or so. The walls curve in, so if I want to go up and still be flush with my vertical panel I must cut something, and it's a lot better to cut the back than the front with its shiny finish.
First piece to go up was the vertical divider.

Then I had to figure out where to screw the poplar support piece. I did that by holding the shelf in place right where I want it to stay. On top of the shelf (the side where I'll put my clothing) I marked along it in a couple spots with a pencil. Then I put the shelf down and screwed in the poplar above that line so that my shelf can screw to it from below.
Here's some more pics;

Note; the poplar support piece I installed to support the length of the shelf was trimmed at an angle at the bottom about 1/2 inch. By cutting the bottom of the piece an angle I can screw in the shelf nice and flat. If the walks were perfectly vertical that wouldn't be an issue.

 

[Luisafernandes]

Last weekend I left the end piece for my other over bed cabinet under some weights. I was hoping 7 days would've been enough to bend the wood, but after removing the weights there wast still not enough bend.
But, by screwing one screw at a time from right to left I was able to make bend just fine.
Here's the result, before I took it down to finish it;

That gap at the end I'm still undecided on leaving it like that or covering it.

 

[Luisafernandes]

My biggest fear was accomplished before sunset.
I had to buy an oscillating saw to cut the ceiling plywood but I think it was worth it.
But first I had to find the center of the ceiling, no easy task with the cabinets in the way. Then I cut a template out of the box the white replacement lid came in. I used that to mark where the cut would go.
I used an old sheet to cover as much as I could of the bed, as cutting that plywood became very dusty.

Then came the foam and finally the Reflectix.

I used a 1/2 inch drill bit (I think. I didn't really look, just grabbed what looked big enough for the saw blade to get in and do its cutting).
After drilling from the inside and before going on top I used the remaining of the shipping box that contained the replacement lid and taped that to the ceiling, covering the hole to prevent metal shavings going allover the interior.

I set up some foam on the sides of the roof and one piece in the middle with two pieces of 3/4 wood across that to help distribute the weight. Then I marked between the holes to better guide with the cut.

With the hole cut I cleaned everything nice with some 70% alcohol.

Then spray painted the bare metal edge with automotive primer, covering the vans paint finish with blue tape.
I placed the unit in place and marked all the little holes, then removed the vent and drilled all the holes. Make sure you have a drill bit that's self tapping, or you'll be sliding that bit allover your nice paint finish.
When the holes were done, the unit went back into place. But before that I run two layers of butyl tape over the screw holes, and where the roof was lower I filled that with an additional three layers of butyl.
Finished with Dicor lap sealant.
Tomorrow after it dries I'll wash the roof to make sure I have no leaks and to remove the metal shavings before they rust.

The sealant is self-leveling and should look a lot smoother tomorrow.

 

[jonthebru]

Very nice job. You thought it through very well.

 

[Free Range Chicken]

Thanks for sharing, this is so useful!.

Did you use a jig saw to cut through the metal? which type of saw / blade? or a circular saw (i'm not sure if that's the right name).

Thanks, I'm preparing to do this same task in the next coming days!

 

[Luisafernandes]

Thanks for sharing, this is so useful!.

Did you use a jig saw to cut through the metal? which type of saw / blade? or a circular saw (i'm not sure if that's the right name).

Thanks, I'm preparing to do this same task in the next coming days!

Hi Free Range Chicken! I'm glad I can help.
I used a jigsaw with a metal saw. Also I stuck blue painters tape to the bottom so as not to scratch the paint.

I think you can see it in the above pic. I was by myself so I couldn't take as many pictures as I would've liked.

 

[Luisafernandes]

Installed top support rail for the above the bed cabinets and cut and stained the doors and frame piece. Also added an L- bracket for extra support;

On the other side I added double roller catch to both doors as magnets would've been impractical;

To help with installation of the small piece that attaches to the door, I left it attached to the rollers and using a marker through the little holes, and with my arm through the other door I marked the exact spot by closing the door against the marker.

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The fantastic vent seems to be holding tight. No leaks, so far.

I think, when I get around to install the roof rack the vent will be much less visible.

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And just installed the rear panel for the above bed cabinets;

 

[highdesertranger]

looks real good luis. you might have said what type of sealant you used on the roof vent, but I missed it. what did you use? looks like a good seal. highdesertranger

 

[Luisafernandes]

looks real good luis. you might have said what type of sealant you used on the roof vent, but I missed it. what did you use? looks like a good seal. highdesertranger

Hi desertstranger!
Dicor lap sealant on top, butyl tape under where the screws go. You can get it at RV places or online.
Thanks for the compliments!

 

[PatrickBateman]

Looks great! I saw you have another post where you were looking for solar panels in the Northeast. I live in NY and I've been looking forever, as the cost of shipping is insane unless you do a group buy with people and order a pallet. The other day I saw these 100W panels, they only weigh 3 lbs and they ship for free:

http://www.renogy-store.com/100watts-bendable-panel-p/rng-100db.htm?gclid=CKDP6qP_i8ECFVEQ7AodymQAJw

 

[Luisafernandes]

Looks great! I saw you have another post where you were looking for solar panels in the Northeast. I live in NY and I've been looking forever, as the cost of shipping is insane unless you do a group buy with people and order a pallet. The other day I saw these 100W panels, they only weigh 3 lbs and they ship for free:

http://www.renogy-store.com/100watts-bendable-panel-p/rng-100db.htm?gclid=CKDP6qP_i8ECFVEQ7AodymQAJw

Hi PatrickBateman!
Thanks for the kind words and the info, I'll check them out...as soon as I have cash : )

 

[Luisafernandes]

Got my Fantastic vent working!
Here's how; I had purchased a 10' 12v extension cord that had not been used yet. I cut off the end that would've been used to plug in 12v stuff, looks just like the socket you see in your car or van, and wired that into the vent. The I the end connects into this battery that I'll charge on weekends;

I used some wire I had laying around to make a channel on the foam by heating it up with propane torch.

Don't heat it too much, just enough to melt the foam but not enough to set the van on fire!
Here's the fan with the trim in place and the wires I ran inside the cabinet;

Notice I used extra strength Velcro to hold down the wires nice and neat against the wall. I don't want to put holes anywhere unnecessarily.
Speaking of unnecessary holes, I almost finished the over bed cabinets. Just need the last piece in the back, which is already cut and is going to stay under pressure till next week

All the hardware's done. And that's where my boo-boo happen. I took the measurement from the opposite side and applied it to this side. Problem is this side's a little smaller (not as tall), and that leaves me with a little hole I wish wasn't there (and that probably you can't see from the picture, but it's there behind the handle). Oh well.

Also added two more lights. All the other ones I had to relocate three or four times since I started building. Good thing I'm using Velcro and not screws!

Here's my remote for the fan;

Last week I started building a little kitchen area. Not to cook, as I don't want to do that in the van (at least not now anyway, maybe one day), but to store the stove, spices, pots and pans and general kitchen stuff. Should be done by next weekend, but here's a pic;

And cut two pieces to help divide the bed from the trunk area as the curtains no longer cover the sides with the cabinets in place.

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Next weekend I'll poly it and screw it in place.

 

[Free Range Chicken]

Hi Free Range Chicken! I'm glad I can help.
I used a jigsaw with a metal saw. Also I stuck blue painters tape to the bottom so as not to scratch the paint.

I think you can see it in the above pic. I was by myself so I couldn't take as many pictures as I would've liked.

Thanks Luis. I'll need to grow some you know what and then do this before snow comes to , Ohio. Thanks again ! !

 

[AimlessWanderLust]

Looks like you did almost exactly what we did to install our MaxxFan.

MaxxFan install

 

[Luisafernandes]

My day so far. Actually it started last night. I was able to finish the third coat of poly before midnight, and today it was dry and ready to go.
I still have to measure and cut the doors, and finish the top part but here's my cabinet;

The cooler goes underneath. I removed the lid hinges, making it much easier to open and I don't have to loose cabinet space.

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The shelves angle in so as not to have a sharp 90 degrees right by the bed.

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Also, there's another shelve not pictures that will go right where the vertical piece ends.

 

[Luisafernandes]

Made a trip to Gender Mountain for a -20 sleeping bag and Mr Heater. No Heaters in yet, but got the Sleeping bag. It has duck fabric on the outside and warm flannel inside.
One tip: if you by plywood don't get birch or oak. I've been using top premium maple from Lowes, but yesterday I needed a specific size I didn't have so instead of buying a full sheet, I got a pre-cut 2' by 4' by 1/2" piece. They didn't have maple in the size I was looking for so I grabbed a piece marked oak. Well, I never had much of a problem with the wood spitting while drilling, not with oak. It splits at the bottom end a few inches in two directions when drilled.
Here's a view from the back all finished;

A close view of the side pieces and how I attached them;

Tip: I wish I had remembered this much earlier. I had been using a file to shave off a bit of the screws if they were too long, then I remembered the cutting pliers.

And here's a close up of what I'm using to hold the curtain rods up;

I used end cap buttons that I got at Lowes. I got them in hardware, in one of those little drawers. Velcro was used to secure it to the wood.
Later I should have much of the cabinet done.

 

[LeeRevell]

That end cap idea for the expandable curtain rods is great! Just what I need for a project, thanks!

 

[Luisafernandes]

That end cap idea for the expandable curtain rods is great! Just what I need for a project, thanks!

Glad I could help : )

 

[Luisafernandes]

Here's my cabinet almost finished, just need to buy more hardware to hang the other door.

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It's not perfect but hey, I can live with it.

 

[amwbox]

Looks great.