Got a van, but it's no dwelling... yet. Looking for advice, pictures attached!

[Naughty Scotty]

Hello everyone!

I bought a new Chevy Express Cargo Van with Access Package in 2005. It has served me well over the last 170,000 miles in my Electrical/IT endeavors during that time.

I am changing gears, and have work prospects in hot, isolated areas of the South with housing shortages. I may or may not end up living in the van permanently. But will certainly be in the van for an extended period of time meanwhile. I am only going for the work experience, then plan to relocate again to a more hospitable environment once the experience is gained. I was a truck driver for 9 years back in the 1990's. The cargo area of my van is a mansion compared to the sleeper I called home for all those years.

I don't have a set budget in mind, but do expect to spend real money on logical amenities and upgrades. The challenges I face with the project is I am currently working 2 jobs to the tune of 70 hours a week to save up for my big move. So not a lot of free time. The van conversion has always been in the plan, but I haven't done anything towards that until I knew I could actually save up for the move. I am proud to say I have saved up quite a chuck of change in the last 6 months! Not counting the conversion costs, I have reached my goal for my relocation budget.

Once I start my project I will start a build thread. Since I have had no advice yet, the priorities as I see them are:

1)Insulation/ climate control? (priority one.)

2)portable power / shore power (My electrical experience has me most interested on this aspect of the build)

3)Next priority?

I feel with insulation and power I can hit the road. Other amenities added as needed? Good personal hygiene is absolutely high on the list. Thinking back to my truck driving days, I know this is going to be my biggest challenge. I like taking showers often, and at will. Especially in the heat. I predict bouts of misery ahead...

I love my van! It is a GREAT work platform. But it seems to me there are probably better platforms for a van dwelling. I hope you disagree and show me the errors in my thinking! My concern is the "access package". Basically, the side window openings have been replaced with remote activated pop up "doors" for easy access to the interior shelving holding parts and tools. It may be tricky to insulate well. I prefer to not "gut" those workings, but to work around it, or ideally, embrace and utilize the unique feature.

Check it out:

The day I brought it home. And the poor 'ol Nissan I retired in the background.

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It has 3 pop up doors. Any one, or all doors can be open.

There is a clunky latch mechanism on the inside of these doors. Are gaps in insulation going to be a major issue? Should I plan on just not using the access doors and insulate as tight as possible? Or insulate the access doors separately and joyously embrace the abundance of air circulation available with the doors open? I may end up in West Texas, South Tx, New Mexico, maybe even Oklahoma or Colorado...

It hasn't all been fun and games... Lots of hard work too:

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And interesting projects like computer servers and a 4000' fiber optic install for a water treatment plant:

The scariest adventure to date was a telephone system install in L.A. I had to park the van unattended in a public parking garage overnight! Not counting my tools, was $60,000 dollars worth of phone system and computer servers! My insurance agent told me I couldn't be covered for any losses. 8-/

I just tucked her in nice and tight in the corner and hoped for the best...

Other then insulating, I am thinking of taking out one side of shelving for a makeshift bed. Leaving the van as "cargo" as possible. I am hoping to just sleep in the van more then "live" in the van.

Any suggestions, and guidance appreciated!

Thanks.

 

[Zil]

First thing, get rid of the Stuff.

 

[wagoneer]

Get a small TT or a 6 x 10 cargo trailer choose which one to live in or work out of. nuff said

 

[Naughty Scotty]

The shelves? Or the job materials?

The shelves... hoping to utilize some.

The job materials... Uh, I thought that would go without saying lol.

thanks!

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Get a small TT or a 6 x 10 cargo trailer choose which one to live in or work out of. nuff said

Sorry I didn't make myself more clear. I'm done with construction. I won't be working out of the van. I don't need the tools or materials. (other then tools needed on any other van dwelling).

 

[Reducto]

Having gaps in the insulation is not that big of a problem - it's not like in a house where you're trying to fill in air gaps. You're already mostly air-tight, you're just trying to block heat that is conducted through the metal and glass.

I used blue insulation foam in my van and am very happy with it. There is another type of foam people talk about on here a lot that is supposed to have a higher R value per inch but I haven't seen that in any hardware store yet so just take a look at what you can find locally. I have a 2" thick slab between the cab and back of my van, which makes a huge difference. For the rest I found a roll of 1/4" stuff and glued together layers of it to fit in various spots. 1 layer under my plywood floor, 3 layers in the ceiling, and up to 4 layers to fill in the gap behind the windows, and finally 1 layer covering it all on the walls. It gets banged up a bit, but it was a lot easier to install than wood and I can cover it with something later if I want to pretty it up.

The most common electrical setup seems to be a pair of deep cycle batteries in the back charged by a combination of the alternator (through a solenoid) and a solar panel on top. If you will have access to shore power you can do without solar. Just get a batter charger or RV power unit.

Don't fret about getting everything perfect - you can always add things as you go. Just get some basic insulation and a bed in there and add more as needed.

 

[decodancer]

I'd kill to have even one of those access doors! I'd screen them on the inside and enjoy the breeze. Stealth, no but comfortable on a hot summer night. Lots of posts on here about shower possibilities but I've got a 20 gallon fresh water tank, on demand hot water heater, and attached spray hose. Drains on the ground or into a catch bucket. I can't tolerate dirty hair and with this setup, I never have to worry.

 

[Ken in Anaheim]

N.S, here's a cut/paste from an old Bob (our founder) post :
I lived full-time in a box van in Anchorage, AK for 6 years quite comfortably, so it can be done. The bigger your space, the more comfortable you will be. However, I have a friend who lives full-time in his Ford Explorer in Denver, CO, so it can be done in a SUV. Here is what I recommend so that you can thrive instead of survive.

Buy a cargo van with as few windows as possible and bare metal walls. Get self-tapping sheet metal screws and run 1x2 inch rails at the top, bottom and middle of the walls, and the same with the roof. They will run from front to rear and you will screw into the vans ribs. At Home Depot buy 3/4 inch thick sheets of styrofoam insulation that are 4x8 feet wide and long.The 3/4 will bend to the curve of the walls. Put at least two layers on the walls and preferably more. Put at least 3 layers on the roof. The roof is most important. Cover the back doors with insulation. Build a wall with 2x2s between the back and driving area and cover it with plywood and styrofoam on the outside and reflectix on the inside by the living area. You will have to cut a door out of the plywood and use hinges to make it open and close. If that is more carpentry than you are up for, hang a heavy blanket on the drivers side and reflectix on the inside . The reflectic is a vapor barrier. On the floor I would just use a carpet pad and cheap carpeting. The floor will be cold, but there is no way to make it otherwise. Buy a tube of caulk and search out as many air leaks as you can find. That will keep heat into the van fairly well.

You want a true catalytic heater, they can be left running while you are asleep and nothing else can. In Alaska I used Olympian catalytic heaters. I turned them on in October and they ran 24/7 until May. I only turned them off to change the propane bottle. Buy an Olympian Wave 3 heater, a 20 lb propane bottle, a regulater, and a hose to connect the heater to the regulater. Follow the owners manual 100% and you will be totally safe. The main issues are the venting to let air in and the spaces around the heater. Follow those and you will be fine.

KinA

 

[decodancer]

I think he is going to be working in HOT southern climates, air flow is going to much more important than extra insulation. 40 years in Florida makes me knowledable about that fact. If you don't want to open the access doors, at least get a good vent/fan.

 

[Bela's Mom]

I love that van! I would put removable screens inside the van attached with Velcro where those pop-out doors are and attach the insulation to the doors without worrying about any gaps. What great ventilation you will have when its warm outside! And you know how warm and humid it gets in the south.

There is a lot of information on showers and power options on the forum. It all depends on how much or how little you want or need. You can always start with the minimum, like solar showers and 12 volt gadgets until you get everything you want planned out.

Looking forward to your posts and pictures as you outfit the van!

 

[Bdog1]

I for one really like your van set-up! I think it "opens" up all kinds of possibilities! (Okay, pun intended)

With shore power your talking AC unit I'm guessing? No amount of insulation will keep you cool without AC. It will only slow the process of baking! I travel/camp in Florida and the power cord is first out last in item. I have a display van (one side windows) EB and a 5000 btu struggles some but keeps it tolerable. It's insulated. A former fiber/splice vehicle by the way.

 

[Naughty Scotty]

Don't fret about getting everything perfect - you can always add things as you go. Just get some basic insulation and a bed in there and add more as needed.

Thanks for the insight! I like your idea about just getting some basic insulation installed and a bed. --add from there. I was hoping to hear that. I'm not lazy, but I plan to keep working 70 hours a week until I head out. Frankly, I'm hoping to work 70 a week when I get down South too. I don't have a lot of spare time to over-build. But I don't want to be under prepared either...

The local HD carries Corning's purple "Foamular" that looks easy to work with. and the 3/4" is really flexible and R-4. If I go with that stuff I will probably do 2 layers where I can. They have the pebbly R-Tech stuff too. I like the foil back, but looks messy to work with. I don't think it has as good an R rating either. --But not sure about that.

I like the idea of 2 batteries, solenoid, alternator. I'm all for solar too, but that would be a project for after I am on the road. For sure I need an RV panel, or roll my own. I'm sure I will want A/C on a regular basis. I hope to find a parking spot and an outlet to rent. If not, generator time...

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I'd kill to have even one of those access doors! I'd screen them on the inside and enjoy the breeze. Stealth, no but comfortable on a hot summer night.

Good ideas! I like the idea of screening in the access doors. Maybe with velcro or something... The bugs are probably a lot bigger then I am use to down there. 8-o

I do want to remain stealth when everything is buttoned up. But ideally I can find some places to park that stealth won't be necessary.

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N.S, here's a cut/paste from an old Bob (our founder) post :

KinA

Thanks for that!

I like the idea of the 1x2 strips. Is it best to also screw the insulation to the strips and use fender washers? Or glue to the strips?

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I think he is going to be working in HOT southern climates, air flow is going to much more important than extra insulation. 40 years in Florida makes me knowledable about that fact. If you don't want to open the access doors, at least get a good vent/fan.

Thanks for the heads up! I will be miserable without A/C. I figured the insulation would be important to not over-work whatever unit I go with.

I am glad to hear the consensus is the access doors are an asset.

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Looking forward to your posts and pictures as you outfit the van!

Thanks for the encouragement! I too look forward to posting my progress. My conversion will be meager compared to many I have seen here. But hopefully you will get a kick out of it anyway...

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I for one really like your van set-up! I think it "opens" up all kinds of possibilities! (Okay, pun intended)

With shore power your talking AC unit I'm guessing? No amount of insulation will keep you cool without AC. It will only slow the process of baking! I travel/camp in Florida and the power cord is first out last in item. I have a display van (one side windows) EB and a 5000 btu struggles some but keeps it tolerable. It's insulated. A former fiber/splice vehicle by the way.

Would you do your generator and A/C different if you had to do it again? Should I be looking at an 8000 btu?

I have an EG3500 which is a good construction site generator. But I figure I would get run off all but the most isolated parking spots if I fired that thing up. Plus it's just too large a footprint to haul around...

I like the idea of an EU2000 and the biggest A/C it will power.

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With shore power your talking AC unit I'm guessing?

I meant to add yes, shore power is Plan A for A/C. Plan B would be generator for A/C. But that would be an expensive option for long term use I would imagine.

I ideally I will be able to tolerate the heat... But I won't be betting on that lol.

 

[blkjak]

welcome from s.w. florida .... blkjak

 

[Starlight]

I've seen one idea where an Airstream was insulated on the outside with a make-shift awning attached to the roof -- maybe 6" off the frame of the trailer -- which prevented the sun beating down on the metal. I'm hoping to do something similar, staking a tarp on one side and over the top of the van to the other side, and over the screen house next to the van.

Since I have a luggage rack and will be using it I can't rig another idea -- which would be to have a folding foam rack on the top, which would open, shading the van and one side of the van. Strapped on, it shades the top, unstrapped, it creates van shade as well as an awning... anything to keep the sun off of the van.

 

[Naughty Scotty]

welcome from s.w. florida .... blkjak

Thanks blkjak!

Really nice build you have.

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I've seen one idea where an Airstream was insulated on the outside with a make-shift awning attached to the roof -- maybe 6" off the frame of the trailer -- which prevented the sun beating down on the metal. I'm hoping to do something similar, staking a tarp on one side and over the top of the van to the other side, and over the screen house next to the van.

Thanks for the tip! I will keep that in mind for a likely upgrade. I could see solar panels on a rack being a win/win.

 

[MLM71]

https://www.conversioncomponents.com/specialty-vehicles/

Hello- I am also very interested in finding a Chevy van with these access windows. Found this company that installs them and have contacted them by email. I have my fingers crossed that they would be willing to install just the windows, not the whole pro package.

 

[bpdchief]

I think he is going to be working in HOT southern climates, air flow is going to much more important than extra insulation.  40 years in Florida makes me knowledable about that fact.  If you don't want to open the access doors, at least get a good vent/fan.

A wise man (could have been Bob Wells) posted somewhere about not worrying about insulating so much in the hot climates because the insulation would trap the heat in the vehicle making it take hours longer to cool down once the sun went down... use reflectix on the glass then concentrate on ventilation. A fantastic fan above your bed would either push air down on you or pull air throughout the van.

 

[jonyjoe303]

I use that rtech foam from home depot, I got it installed everywhere, the more I put in the cooler I get. The more foam you use the less energy you will use to cool down. It works both ways, keeps you cool in the summer and warm in the winter. I use a hotgluegun to install it, it sticks to everything and drys quickly. If you have ryobi cordless tools, they make a cordless hotgluegun. Your van having no windows in the back will make it easier to put foam down. Boxcutter is the best way to cut the foam without making too much mess. 

I'm also 100 percent proponent on using swampcoolers. That will work better than roof vents or fantastic fans, it won't replace what an AC can do but close enough. The hotter the weather the more air your swampcooler has to put out to be effective. I encounter hot humid days where the swampcooler while not as effective it was still better than just using a fan. I build my own swampcoolers which isn't complicated and if I was going to be in texas type weather, I would definitely be using one with 2 car radiator fans (about 12 amps total) to cool something as large as your van in that type of weather. If you have a swampcooler and its not cooling you down, its not big enough.

Your van has a huge space on the roof for a large solar panel. Put a 280 watt panel on there and you can run multiple swampcoolers at the same time all day long. With mppt a large panel will give you about 15 amps. You won't need a generator. I never needed a generator everything is run off my 240 watt panel.

This is a picture of the side of my van where air goes into the swampcooler. Its the only ventilation, all windows,doors,vents I keep close. If its hot and you open some windows, you only let hot air inside your van. 


This is one of the large swampcoolers I built, uses a 6 amp car radiator fan. With a speed control I can throttle it down to less than 1 amp.