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Finally finished up the interior. Got the webasto heater set up and everything functions properly. Few pics of the interior and first trip up at Mt. Bachelor Oregon.

Built cabinets with 3/4" plywood, used a vinyl type sheeting for the exterior and found some nice black rubber edging to give a nice finished look around the edges. I tried to maximize space this time and ease of accessing below the bed so I figures plastic totes that can slide out are cheap and...

Finally made some serious progress as I am trying to get a late season ski trip in with the van. I ended up welding some 2x2 angle iron around the cutout and then bolted that to the van frame where the reinforcements were cut off. For the front lift H bar I ended up cutting through the sheet...

looks awesome. How did you mount the rear hinges? the sheet metal is pretty weak and the thicker frame does not leave much space to work with in-between.

Pop top is mounted. Very happy how well its fits. Still need to mount the the canvas to the van roof, but its starting to take shape. It was a little tricky figuring out how to mount the hinges to support the top since the sheet metal roof is about the thickness of a beer can. I had to get a...

Finally have the exterior of the pop top completed. I got a new rubber seal from the bus depot, I was able to buy it by the foot so that I could get a continuous seal instead of the 2 piece set that is sold for the pop top part and separate luggage rack found on the westfalia. The seal fit...

While I was waiting for the paint to dry I made some artificial rain gutters to mount a pair of roof racks I scored off Craigslist. I was just going to buy a 4 pack, but they were $80ish for L shaped brackets. I had some square tube laying around so I cut it in half long way then welded on a tab...

I used some green Bondo fiberglass to fill in the low areas and shape it close enough. The bondo fiberglass does not really smooth out perfectly since there are little hairs/fibers mixed in so after sanding I decided to use some normal Bondo to get it nice and smooth. I think all in all its came...

yea wax papper peeled right off no problem.

I laid wax paper over the mold so that I could cut out and remove the foam after the fiberglass is set. I used some spray glue so that the wax paperer would stay when I started to brush in the fiberglass resin, but the foam reacted to the glue and it deformed parts of my mold so that was a day...

The foam actually worked pretty well to mold, however it didn't hold its form too well in around the most important part along the roof line where its ribbed. I plan to fiberglass the mold so I figured I could just cut the mold to a general convex shape of the roof a little larger then it needs...

Plan B was to put the pop top on the van and use expanding foam to make a mold in the exact potion that it would be sitting on the van. I used some wax paper to cover the area so that it could easily peel off and started squirting away.

Before I begin I make no claims to be a great welder, fabricator, or builder so there is a chance I may do stuff *** backwards, but if it makes sense to me with my skill set, tools available and materials, that's how it's going to happen. That being said, I only have really seen pics of...

After using my van for the last year traveling the north western US I quickly realized that it would be much nicer to be able to stand inside and have a functional kitchen. That way it would be more of a 4 season camper that I could also use during ski season. I went back and forth about getting...

tires are great, drives very smooth, good in the ice/snow. The double doors are pretty rare, but I see them around. I actually didn't want them because I wanted to build a counter/cabinet across the entire drivers side for more storage, but you work with what you have.

After the lift and tires I went back and forth for a few months deciding what I wanted to do with the interior since it was already a nice conversion. When I was first looking for a van I was envisioning a cargo that I would just strip down and rebuild floor to ceiling, but with conversion that...

First line of work was to strip the stickers, add a lift and new tires so that she was presentable and operational. I went with the Rough County lift for a Silverado that some other members on here mentioned. Everything bolted up easily except the rear shocks do not fit exact size so I bought a...

Hi, I have been slowly building my van behind the scenes while using many threads on here as a resource. I would like to thank everyone else for posting their wealth of information and I would like to add to the smaller, but slowly growing community of Chevy Express AWD vans I have came across...