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Remaining Wall structures in Front Area and Rubber Flooring on Vertical Surfaces Behind the drivers seat, I framed wall structure using 2x2 lumber. This was designed to provide a solid surface for the face, mount the small countertop to, support the folding table and hinge. You will notice...

Headliner Reinstallation, Ceiling Light Install, and Fan Mount With the headliner down, it was time for more holes. 2" holes were made using the Dremel for 4 flush mount puck lights. All wiring was routed along with factory wires on the headliner and fastened down where needed. The goal was...

Thinsulate Insulation Insulation in the vanlife world is a much disputed topic. I decided to go with Thinsulate, just as I did in my sprinter built. IMO, it is the easiest to get the best results with. I toyed with using Havelock wool...but the Thinsulate is SO easy. Cut, spray, stick...

Headliner removal and the dreaded fan hole cut. My original plan was to do everything with the headliner in...but the more I investigated, the more I realized it needed to be better insulated....so out it came. Removing the headliner is not hard at all, just ensure you have the body panel...

Bed Platform (basic framing) For this, I used 3/4" Particle board. Reasoning is, that all of this will be covered with rubber and it cuts and glues VERY straight. With this essentially being the foundation, I wanted it 100% solid. Every joint was screwed with pocket screws and glued...

Rubber Floor installation This was probably my most asked about item in Instagram. How, Where, etc? The material I used was the G-Floor Coin flooring. You can purchase it from lots of places; Walmart, Menards, (sometimes) Costco, etc. This is the same as I used in my Sprinter built. It has...

Floor planking and sound deadening Pretty straight forward. You will see here how the factory seat mount surrounds will continue to be utilized. You will also see how I've integrated the side door step into the overall floor system.

Floor framing and insulation This took some thought and planning, as I needed to ensure that my final floor height would align with the bench seat mounts. It turned out that 2x2s + 23/32 plywood + rubber flooring would match up PERFECTLY. I framed the floor in two sections; front then back...

Interior Removal to prep for the build No surprises here. I did take care to keep all pieces in good condition, because I'm not quite sure what parts of the panels I will need for finish work. You will see that I did cut the panel behind the drivers seat.

The Interior Plan I've been dropping the ball here and not keeping this updated. So prepare for a game of catch up. Next up was planning for the interior. Something we learned from the Sprinter and NARV 1.0, is that we wanted something in the middle ground between just a van, and a full-on...

I just ordered by the part numbers, which I found elsewhere on the EP threads. The parts that I ordered needed to be ordered seperately. I ordered the keys from Summit Racing and Blocks/Shocks from 4 Wheel Parts.

Finally, to round out the weekend...Bumpers were reinstalled.

Bumpers came back from being bedlinered... They came out great. We next installed the lights and re-mounted the plastics.

And then.... Rattle Can Bedliner on the grill, to match the other ABS plastic. I decided to make the Chevy Emblem, the same color as the Black Rhino Warlord wheels. To be somewhat subdued.

Next Up...Removing the bumpers and preparing them to be dropped of for sandblasting and bedlinering. To get the plastic off of the bumpers without destroying the clips, the basically had to be COMPLETELY taken apart.

At the same time as the ladder, I began work on other projects... First up, cutting holes to accommodate flush mounted pod lights in front and back bumpers. Very easy to do. Measure, Measure, Jigsaw, File, Fit, File, Fit, File, Fit, Repeat, Repeat, Repeat.

Next up Alumniness Ladder installation. Overall a pretty easy installation. It requires that you drill two holes in the gutter, and three in the lower body, near the pinch welds. Addtionally, the (3) brackets from Aluminess are not drilled except for the two holes in the lower bracket. It...

Top Clearances (sorry I maxed out the attachments)

Wheels and tires installed. Everything fits perfectly, no rubbing and no trimming required. Wheels - Black Rhino Warlords 17x9, +12 offset Tires - 265/70/17 BFG KO2 (Load rating E, 10 ply) Lift Details: SuspensionMaxx MaxxCam2 Key, Skyjacker BUK2061 2" blocks, Skyjacker H7003 front shocks...

I honestly do not know yet, as I've not been able to get tags yet because DMV closed due to Coronavirus. I suspect it will be the same as I got on NARV 1.0; in the 13-14mpg range. https://expeditionportal.com/forum/threads/n-a-r-v-2008-chevy-express-awd-project.132224/post-1803740