N.A.R.V. 2.0 - 2008 Chevy Express AWD Project (I'm back)

[LYlqoY2Fo]

Storage Cubbies

The vertical supports were added so that cubbies could be built and attached directly to them, and make the most use of the space as possible.

Cubbies were built using basic 1/2" plywood. The finish didn't matter, as it is finished in automotive carpet, and the rough plywood is a good gluing surface. Each cubby on the passenger side was sized to extend as low as possible in that particular void. The rear one (where the factory jack is normall) is SUPER deep, nearly reaching the metal floor of the van.

As for the driver side, it was built as a single large cubby with two sections. All of the cubbies were finished in carpet and 12v LED lights installed in the top back. They will all be on a common switch, to make finding things easy.

These were installed simply by screwing into the vertical supports (with anti-squeak foam between). Before installing the driver side cubby, the AC/Heat duct was redirected using a new duct run to the mechanical area (eventually to a vent in the dinette feet area).

Carpet was sourced from O'Reilly Autoparts.

 

[LYlqoY2Fo]

False Fronts

Now that all of the "guts" are built, it is time to prepare for the false fronts, which will finish it off and tighten everything up. I used to do custom car audio, so this is something I have a lot of experience with. It is a skill that takes some practice with to not waste wood.

The rear false-fronts were made to have the Westfalia look to access the storage, with the rounded look...which I really like. You will also see holes cut for the new rear AC intake and misc USB outlets and switches.

All in all, nine false fronts were required. All of which will be covered with batting and a tweed fabric.

 

[LYlqoY2Fo]

False Front Upholstery and Installation

Now with all the false-fronts prepped...they were all covered with a batting and tweed fabric from Joann's Fabrics. This really softened up the overall interior, literally and figuratively. I didn't count, but I think I used about 8 million staples.

The false-fronts are attached to the structure using small head finishing nails. Doing this allows the panels to be removed if need be, very easily. In the picture you will see "dimples" where these nails are, but once everything is finalized a small pick will be used to free the fabric from the nail head making them disappear.

The last image you will see how the mattress will look. Notice that care was taken to ensure the cubbies stay nice and centered.

 

[borison]

Very nice work, impressive. Looking forward to more posts

 

[LYlqoY2Fo]

Electric Components (and a couple odds/ends)

I got so involved in the electrical work, that I forgot to take many pictures during. But I'll summarize. Battery isolator was installed, running 4awg from the starter battery to the mechanical area. This allows charging from the alternator. A Renogy 1000w Pure Sinewave Inverter Charger and VMAX 100AH AGM Battery was installed. A 120v stealth charging port was installed in the rear, driver side wheel well to allow charging and auto switch to shore power. All wiring was done with 16/2awg marine wire. An 120v outlet was installed in the foot well of the dinette. Battery was properly installed in a separate compartment. Sorry for the potato quality pictures.

If anyone wants any specifics about components used, hit me up.

Odds/Ends - You will see that the vent cover for the new Rear AC/Heat intake and a storage bungee was installed. Also, you will see how the new AC/Heat duct is run through the mechanical area to the dinette foot well.

 

[LYlqoY2Fo]

Cushions and Toilet compartment

Now that the mechanical bits are in and working, moving on to the softgoods; cushions.

All of the cushions were made using the guts from two (because of the odd size I created) 4" Lucid mattresses; one Full and one Twin. Each cushion is backed with 19/32" plywood (sanded and rounded), 4" foam, upholstery batting, then fabric. All in all, 6 cushions were made: (2) bed cushions, (2) Dinette Seat Cushions, (2) Dinette Seat Backs. The dinette seat backs move to fill the footwell, where the table will be.

We choose to use the Lucid mattress over just stock foam, because it is honestly very comfortable. We had the same mattress in our Sprinter and loved it.

The last 5 images, show how the toilet compartment is accessed; remove cushion, slide up panel, and do your business!

 

[Andy G]

Dude. Holy cow.

I’m happy to be able to kind of build a somewhat square bed frame out of 2x4

Beautiful build, and I’ll be hitting you up about the electrical. We’re in the early stages of building out 2017 Express 2500 12 passenger van.


Sent from my iPhone using Tapatalk

 

[bigsam]

Really nice build. Question about the floor: does the wood floor you built float or did you attach it to the van floor or the seat rails somehow? I am planning to build a similar floor in my express van and I'm wondering how necessary attaching the new floor to the van floor will be. Thanks

 

[LYlqoY2Fo]

Really nice build. Question about the floor: does the wood floor you built float or did you attach it to the van floor or the seat rails somehow? I am planning to build a similar floor in my express van and I'm wondering how necessary attaching the new floor to the van floor will be. Thanks

The entire structure is not attached to the van, except for one single bolt/rivnut, which was required in the wall right behind the drivers seat. This was just to firm up that wall structure more in the front. The rear of it was attached to the bed platform. You can see in the picture, I was going to add two bolts, but only one was needed.

As for the floor, it is all floating on the 2x2 framing. Anywhere that wood and wood joined, it was glued and screwed. Anywhere wood and metal touched, a foam (sill plate gasket) was placed there. You can see it here in the picture.

The floor is the anchor for everything else, build on top of it. The bed is attached to the floor with right angles, Wall supports are screwed to the floor and/or bed structure.

There is not a SINGLE squeak in the entire build.

 

[LYlqoY2Fo]

Really nice build. Question about the floor: does the wood floor you built float or did you attach it to the van floor or the seat rails somehow? I am planning to build a similar floor in my express van and I'm wondering how necessary attaching the new floor to the van floor will be. Thanks

As for the side door step, I just built into it, off of the floor structure. I lost about 1" of step, but it finishes it off very cleanly....and again...no more holes needed.

 

[LYlqoY2Fo]

For those interested, here is how the interior looks with the bench seat installed.

 

[whith]

I’ve done something similar although not as tidy and well executed. Great work.

 

[cmarcus]

Holy smokes, this is awesome. As someone eventually (next year) looking to buy/build out an AWD Express, this is giving me some awesome ideas.

One question - when sleeping 4 and the bench seat out, I assume the extra 2 passengers would be riding in the dinette area? I have 2 kids, and the idea (albeit a tall order) is I am trying to think of a way of having similar amenities as you have here, but also being able to sleep 4.

Carry on - killer work!!!

 

[Corneilius]

Nicely done!

 

[LYlqoY2Fo]

One question - when sleeping 4 and the bench seat out, I assume the extra 2 passengers would be riding in the dinette area? I have 2 kids, and the idea (albeit a tall order) is I am trying to think of a way of having similar amenities as you have here, but also being able to sleep 4.

With my build as is...You are correct. If traveling with 4 adults, the bench would have to stay at home and the 3rd and 4th passenger would need to ride in the dinette. If I were traveling with #3 and #4 being young kids, say under 10, you could travel with the bench. Just unlatch it, push it forward (and the front seats forward as far as they go). One can sleep on the floor, one on the bench.

In my last express, we've slept 3 adults in just that situation above (with the seat moved), and it worked fine.

IMO, for you, I would figure out what you need most, storage/gear or beds. If the latter, then I would build the bed higher and keep underneath empty. That way you could but gear OR sleep people on the floor. You "could" add seatbelts to custom seats (I did this in my Sprinter), but honestly, I trust the OEM DOT approved belts more than something I installed. If you are interested in that option, check out SeatbeltPlanet.com

Here are my suggestions for sleeping 4

• Regular height bed platform and floor space like mine - and travel without the bench
• Regular height Bed platform, one on bench, one on floor (assuming one is short enough to sleep on bench)
• Regular height Bed platform, one on bench, one on the inflatable bed things (I know they are made for Sprinters...don't know about expresses)
• High Bed Platform with gear garage underneath (I was going to do this with NARV 1, if I rebuilt it)
• Regular Height Bed platform, one on floor (or bench), one in a hammock-cot above front seats. (Google CabBunk for ideas)
• Rooftop Tent for #3 and #4
• Regular height bed platform and floor space like mine - and bring a "gear tent" to put the bench in outside.

I'm sure others can come up with some ideas too. If it were me and I were building again for my two boys. I would go the floor/bench route until they got too big, then move to a RTT. That would allow the entire build to grow with them...even when they move out...you can sell the RTT.