yager
Wake Forest, NC
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Joined: 06/06/2008
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I was reading the other into thread and figured it was time to say hi in here. I've lurked in the other forums for a while having had a few odd ball campers (converted Kenworth sleeper cab) and now a van..
So I've got an 04' Chevy G3500 Cargo van. I opted for the newer model so I could get the 6.0L and Tow/Haul option for the transmission to better help with towing my trailer and jeep. The van also can do all the other stuff I need done.
My conversion for now will be very basic and flexible. I've read along many of the similar builds that are flexible and easily adapted to various uses. I've picked up many ideas and hope to implement some in mine.
So far I've removed all the cargo racks and drawer units. I then used the pieces to construct a single shelf unit that will be placed on the 'short' side (passenger) The racks are in really good shape and will hold up to the drunken ruffians that are likely to be in my van from time to time..
I purchased a futon/sofa off craigslist and reworked the back portion. I cut the metal down 6" and rewelded it all back. This will allow it to set closer to the wall. I also plan to set the mechanicals on a box and remove the legs. When the unit converts from sofa to bed the seat part lifts up very high and gives easy access to the underside. The reduced width will allow it to fit in front of the shelf unit also.
I have some ideas on the interior and such but will post them when I actually get that underway.
My next steps are to mount the AC in the left rear door below the window and to put some bed liner coating down.
I revamped my pic naming and web dirs so im editing my posts so the pics link correctly.. Here is a recent pic
* This post was
edited 07/31/08 06:58am by yager *
2004 Chevrolet G3500 6.0L\4L80e\3.73s
DIY - Cargo Camper
http://www.epgsoft.com/VisitedStatesMap/
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ARcruiser
Benton, AR USA
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Joined: 12/19/2001
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My next steps are to mount the AC in the left rear door below the window
...that's what I ended up doing a few weeks ago. I wish there had been a better alternative. All things considered, it looked to be the best option for me.
I ended up with a 8,000 btu Frigidaire which had the same size chassis as the 6,000 btu unit.... $188 at a local lumber place.
A local upholstery shop made a vinyl cover for it - $75.
I'll take some pics soon and update the thread on my van.
2 Big Cruisers, The Little Man, and Bailey / ARcruiser's Class B's (the first 8)
Rig #8 Under Construction! / Here's the Project Thread - I'm actually working on it again!
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kking
Lowell, MA
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Joined: 02/18/2008
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Please do.. I'd like to see how you supported it. I have longer range plans of cutting into the high top and mounting one up there, but for the short term I'm open to quicker ideas
The map shows the states my wife and I have driven (or camped) in together.
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bananadanna
Cambridge, MA
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Joined: 11/30/2005
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Welcome to another DIY'r. If I could weld like you my Sprinter would have been less of a "found object" piece of art!
Idea #1 for your a/c would be to cut a hatch just above your shelf.
Mount an a/c on some Accuride slides to make an "a/c drawer".
Open the hatch, slide the a/c through and latch down in camp.
In cooler weather the hatch could be used for an additional screen window or maybe even a beverage pass-through.
I did see a line of low-profile window a/c's. IIRC, a LG model required short/narrow clearances that would theoretically fit through the slider Motion window of my Sprinter. Compact is good and you might find a suitable marine hatch to make it a slick job.
Dan
02 Freightliner Sprinter 2500 long tall home brew conversion
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yager
Wake Forest, NC
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Thanks for the tips. My project will be a bit more utilitarian similar to some other build ups I've seen on here. I'm planning for the rear door A/C as it will put it down low and out of the way. I also have some plans for a simple DIY screen for the rear, which would require the door(s) be open anyway. Also it leaves me the option of replacing the door with a junk yard door if I chose to sell the van.
I have a trip this coming weekend so tonight I'm going to sew up some screen 'bags' to slip over the front door/windows.. I hope to get some pics uploaded on my web site after the sun goes down...
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yager
Wake Forest, NC
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Ok I uploaded a few pics.. Not in any real order..
My van didn't have a 'factory' tow package. To me this was a positive as it meant it wasn't ever towed with. But it also meant there was no brake controller wiring, aux. transmission cooler or receiver hitch.
I ordered an ultra frame class 4/5 hitch from etrailer.com along with some wiring supplies to wiring things up. I went over board with the wiring as I am planning ahead for future stuff. I installed an auxiliary bx under the driver seat with room for 8 circuit breakers. For now I'm feeding the brake controller, the +12v to the trailer plug and +12v for my trans cooler fan. (more on that in a bit)
SO first pic is of my hitch and trailer plug. I punched a hole in the bumper and put the plug where the factory should be putting these things.. I drilled a hole and with a grommet fed the wire up the rear piller/cavity into the van. I used a large covered junction box to connect all the plug wires to the internal wires, and keep it sorta looking neat and easy to trouble shoot if needed. (As an aside I was able to get a FSM on ebay for $30, where I was able to verify the wiring. Factory uses 10amp fuse for each turn signal and brake wire, Knowing that the single bulb setup doesnt draw that much and my trailer bulbs also don't draw much I figure i'll be fine, and if not ill install LEDs)
This only shows the factory junk prior to my adding my box. I welded some tabs on to the seat base and it hold it nicely. This just show that there is tons of wasted space under there.. The seat comes out in <5min. I had to pull wires to the front anyway so I had the frame out all the way and lifter the rubber mat..
Here is my transcooler, it was on sale at summitracing.com awhile back and I never installed it on my jeep, so it got used on the van 
I made the alum bracket (the shiny part) using pictures of how the factor hung their cooler. I also was playing around with my new dimple die set really not needed but oh well  The cooler has a built in thermostat, it wired so it can run on auto and manual on and manual off. I modified the one factory line, basically I cut out the flex hose portion and flared the remain ends to connect to the cooler with some push lock style hose and AN fitting.
Here is a pic in progress..
Also while I was installing the cooler I dropped the trans pan and installed a new filter checked things out.. Looks good for 140k. I wiped the pan down to my surprise the factory 'reusable' pan gasket actually was.. Then with the one hose still off I pumped a total of ~6qts of old fluid out of the converter about 2qts at a time, I added some and ran the van for 45sec. repeat until the fluid comes out looking like the new fluid you put in... I filled the trans with CarQuest Dexron VI(6) full synthetic. That's some good stuff there.
More later...
* This post was
edited 07/31/08 07:01am by yager *
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yager
Wake Forest, NC
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And a bit on the interior..
Here is a mock up oh what interior components ill be reusing and where.
In the side shot my microwave will fit onto the drawer units. All the items will be securely attached to each other and the floor..
I have some floor coating bed liner stuff I need to put down before I get to far along.. 4x4 trip this weekend so for now racks are out and just a futon is in the back to sleep on..
1 front door screen cover is done, I ran out of thread... The old kenmore sewing machine is doing a great job on the fiberglass screening.
* This post was
edited 07/31/08 07:03am by yager *
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yager
Wake Forest, NC
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Opps I realized I don't have a good 'overall' picture...
You can browse the directories on the web server if anyone is interested to see more/other pics...
http://mike.yager.net/g3500
* This post was
edited 07/31/08 07:03am by yager *
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bananadanna
Cambridge, MA
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Joined: 11/30/2005
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Are you powering that microwave strictly from shore power?
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diyvanner
Rhode Island
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Joined: 07/04/2007
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That's a realy great idea with the trany cooler. I put my spare tire up front and never even thought of the aux cooler with the fan. I had to cut out part of my grill to fit an oversized cooler on my 2000 GMC so there must be more room up front on the later models. Enjoyed the pictures and will look for your updates as you go along.
diyVanner
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