Cargo Van Conversion

The rough countertop is now scribed against the sides and back edge. After cutting it to size and sanding the edges, I start working on the front edge. By doubling up the edge, the illusion of a thick top is created. Because of the tension in the wood, I use screws in addition to the…

This Mahogany countertop is meant for the two lower cabinets closest to the sliding door. Made out of 8ft long, 6in wide and 2in thick raw lumber, I first cut it to the four feet length, needed for these cabinets. The next step is to joint the narrow and wide sides at a 90° angle….

I finish all the preparations, before the toilet is installed in the van. The toilet has a mechanism, that allows it to be on a sliding drawer, while being connected to the gray water tank, which is located under the van. I use a PVC connector at the bottom of the slider and an identical…

It’s time to install the new Lithium batteries into the van but first, I need to clean up and streamline some of the old wiring. And I have to add and replace some solar components. I will add 250A bus bars to accommodate the new batteries and the soon to be installed 3000W inverter/charger. A…

I continue with the assembly of the two LiFePo4 Lithium batteries by adding all the components, that connect and control the different parts of this setup. The assembly so far, indicates a slightly taller battery than expected; that forces me to enlarge the storage area access first. Now that I know that the battery boxes…

In the previous video I was unsuccessful in attaching the ceiling panel with the 3M Dual Lock, velcro-type fastener. Today I have a different approach and use the van’s own hydraulic jack with an extension pole, to force the Dual Lock strips together. It is a slow process, where I follow each of the two…

This is one of a series of articles, describing my journey of assembling and installing Lithium battery cells, as part of my van conversion. I will likely make mistakes and may not even reach my goal of a cheap, yet large Lithium battery bank.This is the continuation of Part Two of my journey. Top Balancing…

I continue where I left off in the previous article Van Ceiling Panel Part II. As a reminder, I use an automotive tweed protected against daily wear and UV, very similar in color and texture as the front seats of the van. Before I can install the ceiling panel, I still have to finish and…

This is one of a series of articles, describing my journey of assembling and installing Lithium battery cells, as part of my van conversion. I will likely make mistakes and may not even reach my goal of a cheap, yet large Lithium battery bank.This is Part Two of my journey. A short update I finished…

Several smaller jobs this week. I insulate around the side window and permanently install the Tweed Fabric surrounds. Then permanently install the cabinet underneath and pull some wires for a future outlet and some lights. The main job was to connect the gray water valve’s wiring to the 12V circuit and install a ON/OFF switch…