Project Weekend Warrior (A slow Chevrolet Dmax Express Camper Build)

[Campbulance]

Did you consider putting the sofa/bed at the back of the truck? You could get a storage compartment accessed from outside/the back door this way. This could be a good area for camping chairs and shelter etc ...

It is a possibility. Since I am still in the planning stages I can change my mind. I have a bout a year to build it since that is when my next registration will be due and I want to witch it to RV or passenger instead of commercial. I will have to play around some more. I like this floor plan due to the versatility of being able to add in a platform bed at the back for two sleeping arrangements and open area in the middle for a pseudo living room.

 

[86scotty]

Are you planning on adding a pop top or fixed top? Your current floor plan would be great for that because it is walk through. I would also consider moving the bed straight across the back if you A. aren't going to add a higher top and B. if there are only two of you. If you keep it where it is though you can actually carry on a conversation with any passengers on the couch/bed. If it's all the way in the back (like a Sportsmobile '50' plan) you have to shout to anyone back there, and that's with a quiet gas engine. I've never been in a Duramax and have no idea if they are as loud as a Ford diesel, but if so it might be a consideration.

 

[Campbulance]

Thanks for the insight. As of now I am keeping it standard roof. I have played with putting the bed in the back but havent found a set up I like as much as the original one I have. Planned right now is to have the capability to turn the rear into a bed as well. As far as noise the duramax is definately quieter than psd. I did notice the fan comes on cruising down the freeway, i will have to look to see if that is normal. All in all, it is a really smooth engine to. I have been digging it. I just got to the San Francisco Bay Area and after 3 hours of driving I got into some stop and go traffic and the temp guage stayed straight up and down at 210 and averaged 19 mpg.

 

[ADVANTR]

Hey Campbulance, nice ride. I dig it.

I have a similar van, Savana 3/4 ton, LWB. But it is gas, with the 6.0 engine, and 4 spd auto trans. Check out my build thread for some ideas.

I like your build idea, and your planned layout thus far. Keep it simple to start. You will be surprised how much your build plans may change after you actually use the van for some time. For example, I was convinced I need a galley cooking set-up and a fridge inside the vehicle, but after some months, I have scrapped that idea in favor of portable grill and Engel cooler. Its just more flexible, easier, simpler, cheaper, etc.

Will follow you build. BTW, what are you tracking?? I am trying to put together a WRX for the track in the future myself:victory:

 

[Campbulance]

Hey Campbulance, nice ride. I dig it.

I have a similar van, Savana 3/4 ton, LWB. But it is gas, with the 6.0 engine, and 4 spd auto trans. Check out my build thread for some ideas.

I like your build idea, and your planned layout thus far. Keep it simple to start. You will be surprised how much your build plans may change after you actually use the van for some time. For example, I was convinced I need a galley cooking set-up and a fridge inside the vehicle, but after some months, I have scrapped that idea in favor of portable grill and Engel cooler. Its just more flexible, easier, simpler, cheaper, etc.

Will follow you build. BTW, what are you tracking?? I am trying to put together a WRX for the track in the future myself:victory:

Thanks. I have read your build thread. I must admit I am jelly you found one with such low miles and a pop top. I plan to track my 92 civic hb with a integra gsr motor I just rebuilt. I also have a 89 supra I may take to the track as well. I decided to keep cooking outside using a camp stove, and just bought a 50 quart ice chest for this road trip I am on now.

 

[Campbulance]

Well the van made the 700 mile trip with out to much worry. Some things I encountered was a faulty tire sensor that would go out after about an hour of driving and the fan clutch seems to be engaged a majority of the time while in the freeway. Some thoughts I had were to wash out and clean up the oil cooler/radiator/intercooler of dirt and debris to see if I can get airflow through them to be more efficient.

I went to do some more maintenance this last weekend and got 1/3 of the way through it. I did an oil change on it. The old oil was very black, so it was worth doing the change. I was going to tackle the rear shaft seal of the transmission but when crawling under there I noticed all the rubber was breaking away from the center support bearing. I decided to wait on doing the trans flush/seal/u-joints until I know I wont need my van the next weekend in case I don't get it all finished. I am unsure if the bearing needs to be pressed off and on to be replaced. I did buy the bearing at O'reilly's, hopefully it is the correct one. Its funny how when I dig into things I discover more to do. I figure do it once so I don't have to do it over again.

The van made the 700 mile trip with the way it was and I have to do it again next weekend to continue to help my mom move down to my area. Hopefully the driveshaft can make the trip again. I figured it will be fine.

PS - I still owe pictures of my backup camera install.

 

[Campbulance]

Rear View Camera Install with Monitor:

Well I finally took pictures of the rear view camera and monitor. I didn't take install videos but the process was very easy since I have a cargo van.

The Camera was purchased from Amazon. I was hoping for a shallower angle to get more distance behind the vehicle. It is about a car lengths distance. For example when I am at a light I can usually see the full hood plus the gap of the car behind me. It also has night vision. O was weirded out by this the first time driving at night. It looked like I had a light on facing backwards as I was driving(I leave the system on full time).
Amazon Link


The monitor:
This was just a universal headrest monitor by Sony. Picture quality is adequate(definitely not HD). Decent deal for name brand at $100.
Sony Monitor Although it is no longer sold
Installed:


Install was easier then expected. Pulled the headliner down. Outlined the monitor bracket with a pen and cut the headliner with a large boxcutter/utility knife. Hardest part was cutting the wires for the dome light as it is superglued in. I cut it twhere it comes to the A pillar and installed connectors there when putting it back together.

I also stole my Mom's Futon since we were cleaning out her place to sell. The reason for my last two road trips with the van. I figured this would be good for mock up and use for a while. IT will give me an approximate footprint and baseline to go off of. I loved it and it may stay for a while. Length was just a bit too long but manageable and when sitting gives you plenty of head room. I can even sleep on it in couch form and be comfy.

 

[occasionaldirt]

I have that camera on my Savana - it is adjustable, press the camera up/down & it clicks thru a few positions either down at your bumper for tight parking, or straight behind for long-view of the road.

 

[wheels5150]

Looks like a good base vehicle, but then I am biased.

I keep vacillating between a removable frame that can be a bed and removed when cargo capacity is needed or a full camper interior. It would be nice to still be able to park a Prius in the rear and use the hybrid parking spots.

 

[Campbulance]

Hey Portal,
I haven't done much to the van over the last 8 months. I had a friend organizing a camping trip in Yosemite in September and decided to go. So I am using this as a goal date to get some things done on the van. I have been doing research and planning over this time though.

For some reason I have it in my head that I needed a roof rack in order to start. This way I know where my solar panels are gonna go and the location of my ventilation Fan. After scouring Craigslist I found an used rack locally. The rack is made by system one and is an overall good design, It was made out of aluminum and had a modular extrusion design that I thought could be very versatile. Every cross-bar has a rail for carriage bolts to slide into for limitless mounting options. I bought some roll on bedliner from autozone and painted it on over the last two weekends.






I got it mounted today.




Over 50 mph it has a hum and vibration. I hear that this can be normal for some roof racks, Is that true? Will a fairing on the front side help?

On a side note, this was on sale at wallmart for $129. Similar one at the local home depot was $180 I believe.



Next Step I am going to tackle is installing the ventilation fan. I am going to get the Fantastic-Fan Vent ordered up and possibly the Solar Kit.

 

[Jo_Duval]

nice build so far.

I have an off topic question, what kind of mileage does the D-max give you ?

 

[Campbulance]

nice build so far.

I have an off topic question, what kind of mileage does the D-max give you ?

Its really hard to say. This year has the particulate burn off so it shoves in extra gas at certain times. I know you can eliminate it and gain a few extra. My trip computer has been saying average anywhere between 15-18 mpg on the highway. I want to say that it averages 16 or 17. If I reset the computer and go right onto the freeway it can read 20 but that is ideal conditions and before the emission thing kicks in.

The best part about this van is it doesn't notice weight too much. I have moved a bunch of stuff inside it and the mpg seemed to not suffer. I also towed a car about 400 miles and seemed to get about 13-14 with a 3500lb car on a U-haul trailer. On this tow trip I could feel the weight going up hills but I never floored it either and going downhill I just downshifted into 2nd and cruised down a 7% grade at 55 with out having to touch the brakes (The U-haul Trailer brakes may have been functioning though since they are automatic).

The Diesel GM Vans are hard to find but I have loved mine.

 

[Jo_Duval]

I had a 2005 Duramax truck and loved it. The gf is not convinced about the diesel and the noise of it mostly to get in late in campgrounds or to park stealthy. But i know it would pull anything without ever noticing it. Thanks

 

[Campbulance]

I had a 2005 Duramax truck and loved it. The gf is not convinced about the diesel and the noise of it mostly to get in late in campgrounds or to park stealthy. But i know it would pull anything without ever noticing it. Thanks

Well I will say it is fairly quite for a diesel, don't know once you start pumping up the HP/Tq numbers. All the videos I have seen of the Ford vans seem to be a bit noisier.

Anyways, Small update. I just ordered my Ventilation Fan and will be installing it this weekend. Cutting the hole will definitely be the point of no return.

This was the fan I ordered:
http://www.amazon.com/gp/product/B00IKMC6M0?psc=1&redirect=true&ref_=oh_aui_detailpage_o00_s00

 

[DAV!D]

Just to give you a heads up... Those drom style 110v fridges do not work well on battery power and solar. You need a purpose built 12v compressor fridge. They tend to be in the $500-700 range. Those drom fridges are very inefficient and you add even more inefficiency by running an inverter to power it.. You will end up with dead batteries unless you plan to plug into shore power.