From storm chase rig to stealth campervan

[DPB]

I'm new to Expedition Portal, but I've been doing a lot of reading over the past several weeks here and elsewhere. I currently have a 2012 Express 3500 Passenger Extended 6.0L that is used for storm chasing. We've removed the rear 5th row bench and built a carpeted shelf for luggage. Underneath the shelf, we carry a second spare tire, a hi lift jack, and a couple of tow straps. I've also got a fire extinguisher mounted in the far rear passenger side corner for easy access via the back door. We also added a custom center console, which houses a 2000 watt power inverter, a Cradlepoint mobile internet router, and switches for controlling power distribution and operation of cameras mounted around the van. It also contains storage that we use for our handheld video cameras to keep them accessible. The console also has an attached RAM iPad mount for the driver, and we have a RAM mount on the passenger side for a laptop. I'll try to get some pics of the current mods up soon, but I've got it all torn apart right now getting prepped for the upcoming storm season. Despite all of the additions, we've managed to limit our irreversible modifications to virtually nothing. We had to drill 2 holes under the passenger seat to bring in the 1/0 power and ground, but everything else is completely reversible to factory condition. Which brings me to why I'm here.

The van currently belongs to my business, but after this storm chase season, beginning in late June or so, I will likely be acquiring the van for personal use. My primary use will be stealth camping solo in parking lots while I travel around the country for work. I hate moving into and out of hotels, and I hate the search for hotels every night. My van will primarily just function as a bedroom for me. On most trips, I won't be doing any cooking, and I won't spend a lot of time lounging around in the van. However, I want it set up so that when I do have time to go out camping, I've got a comfortable, practical rig for my girlfriend and me. It will also probably get some use pulling dualsport bikes out to Colorado and Utah for camping and riding with my dad. I'm scheming for a solo trip down to see the Baja 1000 this November too, if I can. That said, my initial mods will be geared towards the solo stealth camping.

So I'm in the research/planning stage right now. My current plans are:
Pull out the center console and all benches
Build a custom seat swivel for the passenger seat (seems everyone that buys aftermarket ends up unhappy with the result, so I might as well start from scratch)
Build a platform for the bed at the rear
Cabinets on driver's side between driver seat and bed, possibly with a basic sink setup
Remote start - Thanks to 86cj for the idea. I may look for a remote starter with interior temperature sensing, for a low buck HVAC solution
Window covers - Stealth is important, so I'll have to do something that isn't noticeable from the outside. It also needs to be easy to uncover the windows for driving.
Ventilation - I don't plan to do any cutting of the body, but I do have pop-out windows on both back doors, one location on each side, and obviously the front roll down windows. I've been thinking about ways to seal around one or both of the back windows and run a fan to turn the factory window into an exhaust fan, then install vent visors on the front windows so I can leave them cracked to pull in fresh air.
House battery - I don't sit parked in one location very long most trips, so I'm not looking to boondock for days without running the engine, but I also don't want to have to worry about being able to start the van. This will power fans, phone charger, laptop, and not a lot else.
Water - I'm undecided about plumbing. I'll start off with no plumbing, carrying fresh water in cans. I am investigating shower options, and may go with something similar to what Accrete uses in his van, likely adding a small stool to sit on since I won't have his high roof. I'll carry a porta potty, but most likely will rarely use it since I'll have access to businesses and rest stops during most of my travel. If I can't find a shower setup I like, I may resort to truck stop showers or just getting a room or campsite every 2-3 nights.
Receiver hitch and motorcycle carrier

I think that pretty well wraps up my long intro post. I can't leave you with no pics, so here are a couple of shots of the van in action in it's current form:


(Not sure why they get flipped when I upload them. They are right side up on my computer. Any suggestions?)

 

[BajaSportsmobile]

(Not sure why they get flipped when I upload them. They are right side up on my computer. Any suggestions?)

Category 4 winds?

 

[DPB]

One thing that has really impressed me about this van is just how well it handles really incredible wind and rain. It tracks straight in very strong crosswinds, and it can basically handle any speed at any rainfall rate. Visibility will be your limiter, and with enough RainX, you can easily run faster in the Express than anyone else on the road. We've had it in hail up to baseball size, and it even took that fairly well. It's got dents, of course, but not the craters you'd expect. The worst we've had happen in hail was the vibration from impact took out a tail light bulb, but the housing wasn't damaged.

 

[Haf-E]

You might consider removing one of the rear windows and putting in an aluminum plate with a fantastic fan in it - easy to switch back and they are reversible to blow in or out. If the plate was painted black it should look be pretty hidden. The vent visors work well but they don't keep out bugs... There are screened window inserts you roll down the window and insert then put the window back up - might be an option. Hard to imagine a shower in a short roof van - I would just pass up that. As far as a toilet goes - a sawdust bucket toilet is good for infrequent use as long as you have a lid which seals well - or an outside vent for it.

 

[DPB]

On the rear window, I've seen a couple online where people have replaced the rear window with a solid panel and mounted the fan to that, but to me, that destroys any stealth factor. When you see that, it makes it pretty clear that it's a camper. What I had in mind was effectively using the window itself for the "cover" portion of the fan for a stock look, but mounting a fan to a panel that seals up to the window sill to get the same effect. Imagine mounting a Fantastic Fan without it's cover on a panel that sits just inside the window. Instead of opening the vent cover, I just open the window itself. That's the theory at least.

I'll keep an eye out for the window screens you mentioned. Do you have a link or product name?

The shower is something I'm just going to have to work out down the road. I'll start without one and see how that works and decide if it's important enough to try to add. For the toilet, I'd be fine with a bucket given that it won't be used much, but for traveling with the GF, I'll need something she approves of anyway, so I might as well just spend the $80-100 and carry a porta potty. Even that will be a tough sell for her, I'm afraid.

 

[Haf-E]

Good point on the rear window - I think your idea of an inner panel is a good one - you could put a couple of small 4 inch computer type fans on the bottom edge - only issue is that they are not reversible. They are cheap on surplus sites and there are wire grills available to prevent fingers from hitting the fans. Typically are brushless and very quite.

Here is a link of the front window vents I was mentioning - looks like they are only made for sprinter and promaster vans though... wouldn't be too hard to make up something similar...

http://www.eurocampers.com/2007--20...--for-models-with-4-or-6-cyl-engine_p_42.html

Sawdust bucket toilets are actually pretty nice - no smell usually and not too funky looking. Much better to dump that a typical portapotty in my opinion.

 

[Mwilliamshs]

...you could put a couple of small 4 inch computer type fans on the bottom edge - only issue is that they are not reversible....

not reversible? didn't realize that but as small and cheap as they as are why not mount 2 facing in and 2 facing out and just turn on the ones blowing the right way? Magnetic sheet (or free RockAuto magnets) could cover all or half of them when not in use.