First attempt at a van conversion(Chevy Express) ... It begins...

lindy74

Member
In 2017 I built my first pop-up camper. I posted the entire process on here and appreciated all the kind words, advice and mostly information.
I finally got the exact van I was looking for for this conversion. I am in the most infantile stage of the conccersion, but gotta get a clean slate to start the project.
2013 Chevy Express Extended 3500 6.0 Cargo. It had 97k miles on it from a sign business. No harsh hauling or towing. Runs great, just needs alot of cleaning.
Ill try to post up every work day with pics and quite possibly questions for the pros out there. IMG_20230921_071226_478.jpg
 

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lindy74

Member
So, I was finally able to get some momentum going now that I have 3 weeks off work.
First and foremost I replaced the stereo and speakers... Priorities while I use it to get materials etc. The van being a cargo basic model had no power licks or windows. I went down the route of trying to figure out if it could just get a door swap or replace the door guts with something from a yard, but in the end went with a $24 keyless entry system from Amazon. Was a bit of work to run all the wiring and find suitable spots to mount the actuators but all in all works great.
The actuators are made to be mounted a certain direction for their throw. The way I mounted them I had to change the polarity of the wires so it wouldn't lock when I click unlock and unlock when I click lock. All in all great add on.
The next project was adding a deck between the seats for the fridge. The seats must have been taken in and out 4 times between the wiring, mat cleaning, and cutting the mat around the new deck frame. It worked out well framing in the underseat subwoofer under the deck. I left breather holes and the foot vent actually blows right down there from the doghouse, keeping it cool in the summer. The sub is pretty impressive as I have a high end system in my truck and this does pretty well for a single 10 powered sub. Another Amazon win.
I got the solar panels (4x100w Renogy) prepped and they should go on tomorrow. I used VHB for my previous truck camper build for the siding as well as many other applications. Really good stuff. I'm torn on trusting it to hold the 4 panels... Let me rephrase, my wife is torn. I would do the 2" vhb on each mounting foot with a overlapping piece of eternabond tape over the top to protect the vhb and add a little extra hold. I think it will be fine, but worst case each panel might get a single screw before the eternabond.
I saw a video for a sprinter build that used Zip System R sheathing for a subfloor. I figured I would give it a try. Expensive stuff, but opted for the 1.5" 4x10, 2 sheets. It has an R value of 6. Plenty imo. The yard that ordered it for me recieved the 2 inch stuff. So it's going back and I should get the right stuff on Tuesday. With the low ceiling, gotta get every half inch I can get.
Lastly, the van had the usual rubber cargo liner which is perfectly cut to the floor footprint, therefore I spent some time powerwashing and cleaning as much of the denim and dirt off so I can use it as a clean template for the floor.

If this was too wordy please let me know and I will summerize future posts, just figured maybe something I ramble might help someone who reads it.

Until the next post! 20231006_144120.jpg20231006_144219.jpg20231006_105212.jpg20231006_144152.jpg20231007_180410.jpg20231007_180417.jpg20231008_091618.jpg20231008_103123.jpg
 

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