Birdman's Not-a-Molester Van

[birdman86]

I've had the only two beyonder's I know tell me I should post up some kind of build thread so here I am. She's slow and will probably stay that way, but I'm converting a straight up molester van into a tent on wheels/mountain biking trail hunter.

Plans include:
- Insulation
- Ventilation
- Auxiliary power
- Bed/Storage/Bike rack
- Fresh paint (eventually/maybe)

I'm also terrible at documenting these things so bare with me...

The van: a 2003 Dodge Ram Van 3500 with 88,000 kms and only a little rust. I was originally gonna just buy a cheap $500 junker but the price was right on this one so screw it, why not. I didn't actually take any day one pictures but here's how it sits somewhere in the last couple weeks. The windows were all painted white and definitely added to the rapey vibe so I've already taken that off in this photo.

http://i.imgur.com/0663rYW.jpg

[birdman86]

Pretty much the day after I picked up the van I was visiting the farm so had access to dad's welder. Bike rack:

http://i.imgur.com/KaPlm1l.jpg

http://i.imgur.com/owM1xYl.jpg

I've since painted it with duplicolor bedliner but the stuff came out super rubbery and I'm not a fan. Next time I head to the farm I might rebuild the thing out of aluminum and use something else to finish it. Steel is heavy, that front wheel cradle probably weights 30 lbs.

PS: Don't judge my welds, it was my first time using a MIG :nut:

[prae]

Where's the bike rack going to sit? what about when wheel size standards change, again? :nut:

I like what some MTB'ers do with tall sprinter vans and build a little garage for the bikes under a bed platform at the rear of the van. Unfortunately I don't think you've got the vertical space.

example:

http://ep1.pinkbike.org/p5pb12683897/p5pb12683897.jpg

I'll be following along- good luck with your build!

[birdman86]

Scraping the rapey window paint. Super easy but super messy, I ended up buying a shop-vac just for this job.

http://i.imgur.com/QQXnf36.jpg

http://i.imgur.com/HEPEEtI.jpg

[birdman86]

Originally posted by prae
Where's the bike rack going to sit? what about when wheel size standards change, again? :nut:

I like what some MTB'ers do with tall sprinter vans and build a little garage for the bikes under a bed platform at the rear of the van. Unfortunately I don't think you've got the vertical space.

example:

http://ep1.pinkbike.org/p5pb12683897/p5pb12683897.jpg

I'll be following along- good luck with your build!

That was the dream but sprinters are a little out of my price range...maybe next time!

The plan is to put the bike as close to the passenger rear wall as possible, and then a sleeping platform along the drivers side. It won't be big and I'll have the handlebar hanging over my ankles but should be good enough as long as I don't bring company.

Basically like this guys layout:

http://i.imgur.com/6H3UMpX.jpg

[Sentry]

https://omgpancakes.files.wordpress.com/2010/01/dajiban-5.jpg
https://omgpancakes.wordpress.com/2010/01/12/dajiban/

You know what to do.

[sputnik]

http://thevanual.com/

http://imgur.com/a/RijZM

http://i.imgur.com/ZEKEobn.jpg

[Thaco]

Originally posted by sputnik


http://i.imgur.com/ZEKEobn.jpg maybe for someone who is 5ft tall..

[xnvy]

Originally posted by Sentry
https://omgpancakes.files.wordpress.com/2010/01/dajiban-5.jpg
https://omgpancakes.wordpress.com/2010/01/12/dajiban/

You know what to do.

I really want to build one. I just have no clue how to do body work and every Ram van here has rust.

Hoping for a Beyonder to build one so I can vicariously live through them. Birdman..? :D

[birdman86]

Originally posted by Sentry
https://omgpancakes.files.wordpress.com/2010/01/dajiban-5.jpg
https://omgpancakes.wordpress.com/2010/01/12/dajiban/

You know what to do.

Man these vans were the ones that sold me on dodges in the first place...but with this being a mtb hauler I need to have at least a little bit of clearance on this thing. For now I'll stick with the a-team stance :burnout:

[birdman86]

Completely gutted and cleaned out. Por-15 on the rusty spots from where the previous owners had their wood floor drilled in.
http://i.imgur.com/p4Z3qNR.jpg

Beginning dynamat...
http://i.imgur.com/CiMGPAj.jpg

Rear dynamatted. It definitely made a difference but not worth the $500 two bulk packs cost :banghead:
http://i.imgur.com/ehJkmB1.jpg

Built a little grab handle (http://www.wranglerforum.com/f19/paracord-grab-handles-how-to-make-your-own-150107.html) to make climbing in/out easier. 10M of paracord and $2 of little clamp things from home depot :thumbsup: (ignore my fat finger)
http://i.imgur.com/HiHn36T.jpg

[birdman86]

First major mod: Install an RV roof vent. Step 1 chop hole in roof, step 2 panic when the storm clouds show up minutes later.
http://i.imgur.com/tEGPPcw.jpg

Perk of buying a dodge: the RV vent has a default spot for the 14x14 opening. Chevy owners have to actually measure the middle :guns:
http://i.imgur.com/k7hG7xL.jpg

Fits!
http://i.imgur.com/cUYkzFx.jpg

[birdman86]

Second major mod is auxilliary power. One day I might go for solar (probably $2000 to set up) but for now a battery isolator will cut it.
http://i.imgur.com/pOVuZ90.jpg

Kill switch for the isolator mostly because I was (still am) stuck waiting on more swag to install.
http://i.imgur.com/LfDTvhT.jpg

4awg wire showed up today and going battery shopping tomorrow so hopefully get this part set up pretty quick

[civic_stylez]

This build is awesome!!

[Thaco]

that looks pretty good so far, if you need more heavy gauge wire, i find the best quality/price ratio, is buying booster cables when they are on sale at princess auto, i think i paid like $30 for a set of 4ga 20 foot cables, so thats 40ft of 4ga, not gonna get that price bulk, and its already colour coded.

[birdman86]

Way behind on these updates... All that rain at stampede kinda screwed up my time frame so I ended up rushing through almost everything just to make a few vacations over the last 6 weeks of summer.

For the “mobile tent” part, first up is insulating the floor - 1” polyiso, acoustic underlay and 3/4” plywood.

Terrible cuts but she fits…
http://i.imgur.com/6kiToka.jpg

Another angle
http://i.imgur.com/mxkuiIe.jpg

Begin cutting plywood. Sawhorses would have been a good investment.
http://i.imgur.com/r5MbePj.jpg

First piece cut, fits preeeetty good. Not great but good enough since it’ll all be covered by flooring or whatever.
http://i.imgur.com/ITF6tJT.jpg

Another angle
http://i.imgur.com/PHlfHbi.jpg

Wood finished, acoustic underlay laid on top. There’s another layer of the underlay under the wood because I had a second roll. I also re-tied the grab handle cause that old blue one was kind of skinny.
http://i.imgur.com/nmzPlv7.jpg