Yet another home brewed van...

[plutonic]

Hey everyone,

Just recently, I started to build my latest van. It's a 2006 E350 Diesel cargo. The interior is pretty much complete now, although I will improve on it as time and money will allow. The next step will be a 4X4 conversion by Chris @ UJOR. I already have most of the parts, currently I'm searching for a suitable t-case.
This is my only four wheeled vehicle, mainly it's a work van but I will use it for everything else... camping, MTB and motorcycle trips, get to hiking trails, etc. I'm trying to make it as universal as possible ( if such thing achievable at all ). Here's a few photos of the most recent work I've done with a help of a good friend. I hope y'all like it.

 

[ujoint]

I think that van is gonna be QUIET!! And I like your color choices, same as mine

 

[plutonic]

Hiya Chris,

Yea... sound insulation somehow has became my obsession... Later this week I will rip out the dashboard -again-, and I will stuff that sucker with some heavy insulation. I still have some more closed-cell foam somewhere...

 

[bknudtsen]

Welcome!

Looks like a good start, with a good friend, and a good shop!

 

[adi]

Did you do any insulation on the floor? I see adhesive sound deadening, foam, wood and carpet, wondering if you did anything more.

Very nice job!

 

[Latetobrake]

Good looking interior and an awesome looking shop!!!!!!!!!!!!

 

[plutonic]

Thanks guys!

First I laid down some butyl based tiles as you see on the photos, I then filled the recessed sections with closed-cell foam. Next was a full layer of 1/2" closed-cell foam everywhere. On top of all that I installed a roll of mass-loaded vinyl. The pictures don't show it but the whole floor received the same treatment, all the way up to the firewall. I did the same inside the doghouse as well but I think I went overboard with the amount of material... the doghouse touches the engine somewhere ( I suspect the downlink pipe from the turbo ). Because of that, the doghouse vibrates a bit, especially at idle.
I bought another doghouse to experiment with different materials and thicknesses. Hopefully I will find the "magic" formula to get the desired quietness with no vibration.

 

[Ironhead]

I never thought about using the silver tape like that, I'm going to have to steal your idea. I noticed you are extending the floor over the step on the side barn doors like I am.

 

[MicroBird]

Hey everyone,

Just recently, I started to build my latest van. It's a 2006 E350 Diesel cargo. The interior is pretty much complete now, although I will improve on it as time and money will allow. The next step will be a 4X4 conversion by Chris @ UJOR. I already have most of the parts, currently I'm searching for a suitable t-case.
This is my only four wheeled vehicle, mainly it's a work van but I will use it for everything else... camping, MTB and motorcycle trips, get to hiking trails, etc. I'm trying to make it as universal as possible ( if such thing achievable at all ). Here's a few photos of the most recent work I've done with a help of a good friend. I hope y'all like it.

That interior looks awesome. I bet it's really quite.

 

[plutonic]

Update:

Following the idea from badgertrek, I installed side vents on my van. I really like the way it looks...

The cuts are straight. What you see here is the paint I applied on the edges to prevent rust, makes the lines look "jagged":

My soundproofing project got another another stage completed. Took the whole dashboard out and installed a layer of 1/2" recycled denim everywhere. The difference in quietness is really noticeable.
After I finished I immediately started to thinking about to do it again with an even thicker layer...

Removal of the dashboard:

The factory sound installation is pretty thin:

Installing the recycled denim:

I used double sided carpet seam tape ( very, very sticky ) to hold the newly installed layer in place:

Installation done, ready for reassembly:

Everything back in place:

:coffeedrink:

 

[CodyY]

Nice work Bro. I'm stealing your interior.

 

[plutonic]

Nice work Bro. I'm stealing your interior.

Thanks! Don't forget to post photos...

 

[mobydick]

Just wondering were you got all the insulation,tape, carpet and foam. This is the next step in my van.

 

[plutonic]

Just wondering were you got all the insulation,tape, carpet and foam. This is the next step in my van.

Insulation, aluminum tape and Reflectix is from Home Depot (if I'd do it again, I'd use recycled denim everywhere...). The carpet is from www.OnlineFabricStore.net. Make sure you order enough, it's very frustrating when you run out of fabric and you have to wait a few days to get more.... I used 3M 80 spray glue everywhere. I tried the Loctite brand but did not hold up as good as 3M.
The closed cell foam is from a local shop..it's better to find a local supplier, because shipping can be pricey. Make sure that you check Big Lots or the likes, because sometimes they sell closed cell foam yoga mattresses or gym floor tiles for a very good price.
The mass loaded vinyl is from ebay (http://www.ebay.com/itm/MLV-ACOUSTI...022&category=63894&cmd=ViewItem#ht_687wt_1347), there are a few guys selling them. I got the 1sf/1lb version. The sound deadening tiles are from www.sounddeadenershowdown.com ( if you have a friend working in the telecom industry, ask him if he can get you butyl insulation tape. Use that with aluminum tape. It does the same like the tiles but it's extremely cheap).
Hope this helps. Good luck with your project!

 

[FAW3]

Your project caught my eye...and years ago I used similar color carpet to do my Ford van...3M adhesive and canned carpet adhesive along with some trim washers & screws and there you are. You have a neat finished look, and if you ever need to get behind the panel to add/change something...it's easy.

I used a very heavy, dense, short nap carpet that resembled yours. It came Scotchguarded. What was really nice is that spilled liquid just sat on top...did not absorb into carpet for several minutes. Even typical beach sand sat on top and could be brushed out easily.

Nice work!