AT Overland- 2018 Promaster Build ( Mountain Bike Adventure Van)

[Cummins_expo]

We have been getting requests regularly to build out adventure based vans, we have done several but not really documented them before. A local couple had contacted us to build them a Promaster Adventure Van. Their primary focus was to transport mountain bikes and have a place to stay in between rides. They typically go out for 4-5 days at a time.

Build- 2018 Promaster
Focus- Moutain Bike Hauler/ Camper
List of adds:
Solar
Fresh drinking water
Outside Hot Shower
Space to fit 3 LARGE mountain bikes inside
12v Fridge
Max Air Fan
Porta potty
Cabinets for gear and clothing
Smally galley to prep food
Outside hook up for outdoor cooking
Led Lighting
Power ports to charge

 

[Cummins_expo]

Now the part people actually want to see pictures !!!

The first step get the Promaster drawn in 3D

Fat mat the interior

Using the 3d models really expedites the panel making process

Fire up the Shopbot


All the floor insulation cut on the shopbot same as the subfloor

Sub floor will get sealed and treated

 

[Cummins_expo]

Next we go over some layouts of the interior with the customer:

 

[b. rock]

Is that bench going to move or be static? I have a similar design in mind for an E350 but was thinking of making the bench an option for extra campers, if need be.

 

[Cummins_expo]

The original design allowed the bench to serve as a bottom bunk. This customer decide they wanted a fixed bench and bed- I will see if I can pull up images of the design

 

[Cummins_expo]

This was the idea ( with smaller galley cabinet) if you wanted the ability to sleep multiple- The lower bed platform uses the wheel wells as support

 

[Cummins_expo]

The not so exciting part of the build:

Insulation and rough wiring

We have a hole in the roof

 

[Cummins_expo]

Now things start to get fun-

Gally kitchen

Garage and base for bed platform- This will get bed lined so its waterproof and activity proof

 

[Cummins_expo]

Garage sprayed will get aluminum extrusion on the corners and be the base for the bed platform

 

[b. rock]

That looks better than expected. Does covering wood with bed liner really waterproof it?

 

[Cummins_expo]

That looks better than expected. Does covering wood with bed liner really waterproof it?

It first gets a coat of poly- The bed liner material is the same stuff we coat our under bed boxes with. This will also give it an "outdoor activity" safe surface toss muddy gear, bikes, you name it.

 

[Goonie]

man that shopbot looks like a DIYers wet dream!

 

[Cummins_expo]

Yes it is!

 

[Cummins_expo]

Once you spend a little time designing you can create easy "Ikea" assembly drawers.

Pre-drilled holes for your soft close drawer slides

self-aligning joints and groves for bottoms

 

[Cummins_expo]

And now to see if it all fits together

Drawers will get slam latched and a faceplate