Build thread: "Dave, The Granite Tortoise," 2011 Chevy Express 2500 Quigley 4x4

KirkL

Member
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I just purchased this 2011 Chevy Express 2500 Quigley converted cargo van with passenger windows, and it has been dubbed thee, “The Granite Tortoise.” I almost bought a white passenger van a few months ago, and I would have named that one, “MichelVANgelo, The Albino Turtle.” Michelvangelo didn’t feel like the right name for this grey cargo van, so I had to pivot.

The body and paint are in really nice shape for a 2011, but the wear from Pennsylvania winters is apparent in the undercarriage. So first, the plan is to send it to my guys at Merritt Motors for a deep chassis cleaning, rust removal, and new undercoating. A foundation evaluation and repair, if you will, before I decide to sink too much money in the build. For the next few months after that, I’ll use my camping equipment to play with the van and figure out exactly how I plan to use it for weekend mountain and beach trips. I flew up to the seller to drive home over the weekend, and sleeping in the humidity on a little inflatable backpacking mattress that fit into my carry-on is NOT part of the long-term plan, but chasing nice weather on a more comfortable insulated mattress should work fine for awhile.

I’ll be on the hunt on Facebook marketplace and in local junkyards for deals on interior cab upgrades, including basic creature comforts like nice seats, an upgraded stereo, and cruise control, as well as searching for bargains on other longer-term upgrades. Having the cargo van means I don’t have to worry about gutting the interior, removing the rear airbag, or removing the seat-rails, so I have that going for me, which is nice.

Long-term, I want to add a high-top and do a Vanagon inspired interior build with a rear bench seat that folds down into a full-size bed (probably a rear extension platform with storage underneath to reach full-size length), a small kitchenette with sink and fridge, interior storage cabinets, 12 volt A/C, solar panels, and auxiliary power system. No toilet, shower, or permanently installed cooktop for relative simplicity (maaaaybe this outside solar shower I saw on YouTube). Clarification for anybody from my God-forsaken HOA who happens to stumble upon this thread, this is an Overland Van, and NOT a motorhome, RV, or camper.

At the end of the interior build, my plan is to upgrade the suspension with progressive rear leaf springs to account for the extra weight from the build, fresh shocks, upgraded wheels, and all-terrain tires. I’m planning to size up only slightly on the tires to mostly maintain the existing height and minimize negative impacts to fuel economy.

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FAW3

Adventurer
Looks like a great foundation. Be watching how you build it out.

Way back in the day I rigged up a Ford van…started with a bare interior. I really learned to love, in no particular order:
venting windows with removable screening, a powered roof vent that could reverse and blow air onto a comfortable bed, a simple spigot jug over a dishpan for my water system & good insulation.
 

ExpoMike

Well-known member
Congrats on the new rig. We picked up our 2013 GMC Savana back in March. It has an Advanced 4x4 conversion (similar to Quigley) and have been starting my build. Recently had the high top installed and it's a total game changer. Still getting used to not having to stay hunched over when getting in the rear area. :ROFLMAO:

Good luck on your build!
 

KirkL

Member
looks like a great starting point. what's it like in the back? trimmed out like a passenger van, or bare like a commercial?
Cargo in the back with plywood and plastic paneling. That will get removed when I eventually put in thinsulate. Also has rear A/C, and I’ll probably remove that if I decide to add 12 volt AC.
 
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KirkL

Member
I found what I think was a 20 inch Fiberine aerodynamic top, and I was planning to go to the salvage yard yesteray morning after a failed removal attempt the previous weekend, but looks like the van with the hightop was removed from their inventory Friday afternoon. I got all the bolts off, but the reverse flange adhesive is no joke. I was going back with a ladder to try to break the adhesive from outside (van was somewhat elevated on old wheels and I couldn't reach the outside at all with my t-rex arms that also inhibited my professional basketball career, along with my overall lack of height, talent, and athleticism), as well as some longer blades and more battery power for my sawzall. MY stupid real job got in the way for this find. I am still somewhat torn on which hightop to try to get between Fiberine, Mory (Quebec), Wasatch (long ass trip) , or HTV (even longer ass trip). I might try to contact a few southeast shops to see if they would install a new Fiberine shipped from LA. I'd love to do a Tufport or HTV if they ever had an installation option near Toronto. Bummer that eastern North America only has Mory, which is still about 17+ hours from me.

Merritt Motors completed the dry ice cleaning, laser rust removal, and new undercoating.

I have a couple small projects planned for the short-term:

1) Install a nicer leather steering wheel with radio control and cruise control buttons purchased off Facebook marketplace for $90.
2) Fix or remove the dropping spare tire mechanism.
3) Take to the dealer to install a cruise control module and fix what I think is a wheel speed sensor issue that's making the van shout at me about ABS and stabilitrak servicing.
 

KirkL

Member
How bad was your rust and how did the blasting/laser/treatment come out? I have an appointment for the same in about a month
Lots of surface rust, and one of the body mount perches was pretty rough. I thought they might end up tossing my hitch, but they ended up salvaging it with the laser. Because of the pitting, it doesn’t look quite as slick as it did on my Land Cruiser, but I don’t spend too much time looking at my undercarriage. I just wanted a little extra confidence before I started sinking money into a rig with a rusty frame. This instagram reel shows the two stage undercoating I got, and features my recently sold TLC.

 

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