Cold Smoke - Ski and Mountain Bike basecamp - Ford Transit USA Forum
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post #1 of 27 (permalink) Old 04-02-2017, 06:56:PM Thread Starter
Ben
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Cold Smoke - Ski and Mountain Bike basecamp

I finally have it ! It's time for a real build-up thread !

So, I got my hand on a white 148 medium roof 2016 Transit cargo van.
It's an "old" rental truck, 14000km, only windows on rear doors, empty of course... for now !



I'm super stoked and even though it's gonna be a slow build I can't wait to start converting it !

Here's what I already have in the garage, waiting to be installed :
- Maxxair 5100K (will have to wait for a more appropriate weather)
- Solar Panel : Solar World SM300 (300W)
- MPPT charge controller : SolarEpic 4215BN (+remote and temp sensor)
- Samlex Solar SEC-1230UL battery charger
- Fuse block, bus bars, a couple 40A breakers, battery switch
- LED lights (4 to start with...)

- 2 Scopema swivels are on their way.

What I'm still thinking about and what I'm working on :
- Roof rack to support the solar panel, I'll go with 8020 profiles + custom towers and brackets (it's cool to have even a small access to a machine shop :p)

- Roof fan adapter, same principle as Hein's...

- Battery : I calculated my future needs (when the conversion will be complete) and I will be comfortable with 240 Ah (2 days using everything with 0% recharge and stay above 50% on the battery). At first I was looking at 2x Full River DC250 AGM batteries (6V/250Ah) which I can have at a descent price but lately I found a place selling the Trojan 8D battery (12V/230Ah) on sale $100 cheaper that the FullRiver.. it's one 12v battery so if I ever want/need to install it under the van it's gonna be more of a challenge, but I don't plan on it anyway. I liked the idea of 2x 6V batteries because it offers more flexibility regarding how I can make them fit in the van layout. But the price difference is interesting, I'm sure I can leave with 20Ah less, I'm sure I'll manage to fit it in my layout too... and it's a Trojan (should be a better product)... well, still need to think about it !

- Rear seat : The van came with 2 front seats only, I'd like to be able to add a 2 seat bench on L-Tracks just behind the front seats for the times I'll be traveling with more than one passenger..

- Sliding door window, waiting for the CR Lawrence offering..

- Layout... I gave myself all the summer to try different configurations. One thing that I'm sure of is I need an elevated bed platform in the rear to store my bike under the bed... that's pretty much it !

- Wiring Diagram : I already have some of the stuff, will see how I make it fit in the van and measure the wire lengths I'll need... then Circuit Wizard to find out the wire gauge.
For now nothing to charge the house battery when driving, only solar and shore power for that... but in the future I plan on having an inverter to feed the "shore" charger with the car battery/alternator.
Here's my diagram so far, if you see missing mandatory items please let me know !



to be continued...
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Last edited by Ben; 04-04-2017 at 07:34:AM.
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post #2 of 27 (permalink) Old 04-04-2017, 01:16:AM
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Welcome and congratulations with exciting build plans. It is our opinion that batteries under the vehicle is better for stability (mass below CG rather than above) and safer for occupants (your precious cargo) in event of a collision/roll over. We do regularly ship our products to Quebec so happy to provide an adapter for your vent install. Take a look at our bed platform design. It's completely non-invasive and safely secured so you can do something more permanent later on.
All the best, Hein.
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post #3 of 27 (permalink) Old 04-04-2017, 08:09:AM Thread Starter
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Originally Posted by Hein View Post
Welcome and congratulations with exciting build plans. It is our opinion that batteries under the vehicle is better for stability (mass below CG rather than above) and safer for occupants (your precious cargo) in event of a collision/roll over. We do regularly ship our products to Quebec so happy to provide an adapter for your vent install. Take a look at our bed platform design. It's completely non-invasive and safely secured so you can do something more permanent later on.
All the best, Hein.
Thanks Hein !
I do have a CNC router at home and have some leftover Celtec from another project so unless I need to order more material I'm gonna be able to make a vent adapter myself. Since I will install the roof fan between the 2 rearmost ribs I won't be able to fit an "all around" lower adapter.. 2 strips lengthwise will fit but I have to take a closer look on how to secure the screws/bolts on the van ribs (width-wise).

I've been following your work on battery mounts, it's very interesting but If I want to go that route I'll have to have two 6V batteries, I don't think a 8D sized Trojan will fit under the van and actually I'd even have to check if you managed to make 2 "GC2" sized batteries fit with your battery holder (they're tall !!).
I have to say that right now the "1x Trojan 8D" option is on the top of my list, I'm sure I can find a way to hold it securely inside the van but you're absolutely right about the fact it would be better installed under the CG..

Oh and I changed the links to the pictures, I didn't see the links were broken..
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post #4 of 27 (permalink) Old 04-04-2017, 03:44:PM
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Looking good
I'm in the same design phase as you with mtn bikes. My 29'rs are 37" tall w/o frnt wheel, with a Med roof I think the best way is a removable platform bed, one height for sleeping (able to sit up) and one height for storing bikes. I've been recently toying with the idea of a trampoline type of platform which would allow me to store it rolled up in the van when not in use, which is most of the time when I don't do over night races.

My friend showed me a picture of a sprinter with a bed platform that slide out along with the bike storage platform, pretty cool, you can sleep under the stars.

Anyway I see your not using an inverter only a charger?

Keep the info coming, bike haulers and campers can be a challenge for bed location and design.

David
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post #5 of 27 (permalink) Old 04-04-2017, 03:46:PM
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Quote:
Originally Posted by Hein View Post
Welcome and congratulations with exciting build plans. It is our opinion that batteries under the vehicle is better for stability (mass below CG rather than above) and safer for occupants (your precious cargo) in event of a collision/roll over. We do regularly ship our products to Quebec so happy to provide an adapter for your vent install. Take a look at our bed platform design. It's completely non-invasive and safely secured so you can do something more permanent later on.
All the best, Hein.
Hein
Do you have the name of your web sight?

David
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post #6 of 27 (permalink) Old 04-04-2017, 05:26:PM
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Hein
Do you have the name of your web sight?

David
You can follow our Transit build on this forum.

Considering a 130WB medium roof for sports wagon + R&D work

And our ebay store is impactproducts.
we also own DIYvan.com where we have our contact info.
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post #7 of 27 (permalink) Old 04-04-2017, 07:26:PM Thread Starter
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Originally Posted by louieless View Post
Anyway I see your not using an inverter only a charger?

Keep the info coming, bike haulers and campers can be a challenge for bed location and design.

David
No inverter for now, it will be summer soon so I should be able to run 100% on solar power. And the "shore" charger is just a backup plan if needed.

The thinking is going on extensively, the actual building will have to wait for better weather, I still have snow around the house and it's still ether cold or raining.. not a good time to install a roof fan (which will be one of my first mission), and the swivels are still on their way !
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post #8 of 27 (permalink) Old 04-06-2017, 06:39:PM Thread Starter
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Getting a bit busy in the shop while it's raining...
made a couple parts on the CNC to test if my measurements are OK.

First a plywood mock-up for the roof rack towers (for solar panels) , then a MDF roof fan adapter to double check before I cut my only plastic leftover...
Attached Images
File Type: jpg tower_template.jpg (131.2 KB, 89 views)
File Type: jpg roof_vent_adapter_template-4.jpg (155.6 KB, 90 views)
File Type: jpg roof_vent_adapter_template-2.jpg (171.2 KB, 91 views)
File Type: jpg roof_vent_adapter_template.jpg (139.3 KB, 85 views)
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post #9 of 27 (permalink) Old 04-06-2017, 08:12:PM
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Cool! Good luck, just got started myself.


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post #10 of 27 (permalink) Old 04-06-2017, 08:53:PM
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Garage
****. All you guys with CNC's make me jealous.


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