Converting a Box Truck?

[mariasman]

I know there are several threads on this topic. I just posted a question in the RV forum about the durability of commercial RVs. In short, I just examined some models at a local RV dealership. I was astounded at the poor build quality. I would never purchase such a vehicle based on my observations (can you say money pit?). Now, maybe folks getting a crazy good deal on a well maintained used RV can be happy about the purchase, but $60K for a low end Class C? I don't think so. So, I went online to find the price for new box trucks with space on par with a Class C RV - same E450 chassis. Looks like they sell in the low to mid $30's. Perhaps I am being naive, but not counting labor costs which I would do, it seems I could convert such a vehicle to an RV that is at least as functional and FAR more durable for less than $20K - including generous solar with battery storage, excellent insulation, roof reinforced with FRP panels, and a functional shower (vs. micro shower in the Class C). In other words, the total cost would be well under that of a new commercial RV of similar size.

So, anyone with experience, what can you say about the durability of commercial box trucks? I already know commercial RV's a poorly constructed. Is the stock box on commercial box trucks durable? Do they make genuinely durable conversions into RV's? Pros/cons?

Thank you.

 

[masterplumber]

I'm not sure you can get a brand new E450 with a box for the mid 30s - if you can that would be a good deal. Lats year I bought a new 4x4 dually - I know, apples and oranges. But I was originally looking at 4500 series cab and chassis trucks and putting a service body on it. The cab and chassis trucks were more than the pickups as they don't have the factory incentives like on the pickups. And then I still had to buy a bed and install it. Maybe vans are different, but I would talk to the dealer and get first hand info on that part.

As far as the rest, yep, you're right. You can definitely build better quality for less money, and have a better layout for your own personal needs. That's why so many on here do that. I would put the quality of work and products of my cargo trailer up against any travel trailer, and I have less than $5000 in it total including the bare trailer. In your case I think the ideal situation would be to buy a low mileage 3 - 4 year old box truck - that may be hard to find as they tend to get used hard commercially, but they occasionally pop up when a company tries to grow to quick and has to liquidate or something.

 

[BradKW]

Yep, your math is pretty much what I came up with too. I went the used route and got a E450 with a 7.2 diesel, 135k, for $10k...really nice deal. In general I'd recommend buying used, even if its only a couple years old...just the upfitter cost of box takes a huge drop as soon as it drives off the new lot. Link to build is in signature...

 

[mariasman]

Brad, yes, what you did is what I have mind. In fact, your build is closer to what I imagined than anything else I've yet seen.

How is the Peal and Seal on the roof working out? Any concerns at all?

I like how you recessed the batteries in the floor. I had determined independently that I would install as many panels as possible while also going 24v. My position is if the roof will support it, then why not? I've got quite a few unconventional ideas, and many require abundant energy.

Would you change anything?

Mark

Yep, your math is pretty much what I came up with too. I went the used route and got a E450 with a 7.2 diesel, 135k, for $10k...really nice deal. In general I'd recommend buying used, even if its only a couple years old...just the upfitter cost of box takes a huge drop as soon as it drives off the new lot. Link to build is in signature...

 

[BradKW]

The peelNseal + Eternabond tape border is fine...I wanted to paint it, but nothing really sticks well enough at this point. Most of it is covered in panels, but what is not will eventually degrade from UV exposure. I figure in a year or two it'll loose the "newness" and will allow paint to bond well enough that I'll do it. Obviously if I had a choice, I would have liked a metal roof.

When I began, I had high hopes of completing the build in 6 months or so, but that's turned out to be very unrealistic given what I'm trying to do and the weekends I have to put towards it. One big benefit is that my plans have plenty of time to change and evolve. I am certain that if I'd been able to take off work and just build the truck, I certainly would have a number of things I'd do differently. But as it is, if something "different" comes up, odds are I just work it in.

 

[DannyB1954]

The problem with commercial vehicles is insurance and registration. Some States make things easier than others, (insurance is regulated by State laws).
I am in Nevada and wanted to convert a step van. My insurance would not take it as it was a commercial vehicle, and commercial carriers did not want me because I was not a business. You can lie and get insurance, but if you file a claim, they may not pay claiming fraud on your part.

Get a vin number from a truck similar to what you want and go shopping for quotes. Make sure you give the insurance company the vin number.

 

[mariasman]

Questions about used box trucks:

First, I expect many were abused. Is it sufficient to take a unit to a qualified mechanic for inspection to determine its condition? What sort of inspection is necessary and what would this cost? Second, I've seen what appears as good deals on Craigslist. Are there any brokers out there that help in vehicle transactions between individuals? It seems this would be a useful service. Finally, roughly how much does it cost to replace the gas engine and/or transmission in such a vehicle? ...Assume remanufactured components. What other major repairs might be particularly costly but necessary to keep such a vehicle in acceptable running condition (not considering the obvious like collision damage or gross corrosion)?

 

[BradKW]

I think the first thing to really understand about box trucks is that you are simply buying a Chevy, Ford or GMC truck or van, with the rear body removed and a box stuck on. You could easily purchase it without the box and it's called a cut-away, ready for a flatbed, dump, box, etc.

Point being, my E450 Box Truck is really no different than a Ford E250 van when it comes to mechanics. Bit of a generalization, but you can Google the rest once you see that a "box" doesn't make it different...

 

[mariasman]

Yes, I realize they are mechanically no different than conventional trucks. I suppose I am just being cautious. I have some limited engineering and mechanical background, but no automotive experience... and I have never owned a truck before. I definitely am sold on readily available and proven gas engines. I like diesels, but I would not drive enough to justify the added expense.