Wilderness office 2002 e350 4x4 build out

[Nazurus]

Hi all

So I’m doing this custom build out on my own, first time doing anything like this. Thought I’d post up here to get some advice and insights.

All I need is LTE signal to work , and I wanted to create a rig that can take me anywhere to setup mobile living quarters / office in wild out the way wilderness places.

I’ve already cut the roof off

And welded a frame to achieve 2 basic things
- high enough to provide ample head room
- strong enough to build a patio deck on top
— this is critical .. (being able to roll out the Persian rug and pillows on the roof deck is what it’s all about )

Things I’m hoping to achieve:
1) roof hatch and ladder inside van to access the patio roof deck without exiting the van... anyone know a good premade windowed bubble hatch I can buy online ?

2) strong arm lifts and hinders on the 2 large windows down the drivers side , so that window glass can open out to 90°, anyone seen this done ? Ideas about it ?

3) I want to make the read doors swing all the way out and around and fold flat to the sides of the van, like the ford transit or sprinter vans .... wondering if anyone has attempted this ? Or seen an example ? Or has idea how to do it ?

4) metal frame will be sided with sheet metal- any ideas on what metal to use? ESPECIALLY interested in what anyone has to say about waterproofing !

5) I want to put windows in the sheet metal siding of the custom top. Any good threads on this type of thing ?

Ok that’s it for now. Will post updates on this thread .

Thanks for checking it out .


So here is how it’s going so far

 

[VroomSIX]

Looks like an awesome project. How are you gonna skin that frame? Fiberglass?

 

[Paddy]

Glass is gross! Use aluminum sheeting like real trucks. It comes painted white. Glue and screw. Or rivet.

 

[Nazurus]

Glass is gross! Use aluminum sheeting like real trucks. It comes painted white. Glue and screw. Or rivet.

Nice! Yes I was hoping something like that existed ..
I.e. already painted white and exactly what I need .

Any ide on where to source that stuff ?

 

[brp]

Sheet metal supply places have painted sheet metal. There is also "color clad" which is a colored, plastic film on the metal.

I work some with "composite" at work, that is what sheet metal guys call it. It is a sandwich, aluminum-stiff plastic-aluminum. If you wanted something with a little more rigidity, it's a really nice option. It's about like 1/4" plywood in terms of rigidity and is roughly 1/4" thick as well It comes colored in most cases. You could google "architectural sheet metal" to find more about composite.

 

[GoinBoardin]

BRP, are you talking about sign material? I sided my camper in E-panel (well, off brand stuff, half the cost). 0.008" thick painted aluminum on each side of ~4mm polymer. Sikaflex 252 was used to bond it to my tube frame. It's tougher than you'd think, and reasonably lightweight. I didn't use rivets: no holes = no leaks.

Sweet 4x4 van, btw. Should be a solid platform.