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2020 AWD Transit 250 MR
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Discussion Starter · #1 · (Edited)
My goal is to build a Ski Van for the winters in the West but mostly around Lake Tahoe and Mammoth area. Next Summer we plan on taking it to Alaska too. I started with the floor. I bought some marine grade 3/4 " plywood and painted it with some Kilz Mildew resistant primer. I'm over a month into this project and will try and post pictures of my progress. This is my first van build so any advice will be helpful and appreciated.
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My sound deadening stuff is on back order.. just waiting... Looking great so far. This is my first as well and need pics like your for help!! Thank you.
 

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Discussion Starter · #8 ·
We didn't want a lot of windows so we installed 2 small ones in the back of the van, they do open and have a screen. Install went well, and I had to make a plywood back for them to tighten up to. Tested them for leaks and they passed!! Still thinking about adding another small window on the sliding door.
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Be sure to thermally isolate the 80/20 from the van steel. If you do not then 80/20 temperature will be close to the van steel temperature. Neatly bypasses the insulation.

Some useful information on using 80/20 for a conversion:

 

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Discussion Starter · #10 ·
Be sure to thermally isolate the 80/20 from the van steel. If you do not then 80/20 temperature will be close to the van steel temperature. Neatly bypasses the insulation.

Some useful information on using 80/20 for a conversion:

Really appreciate the link to your build and all the helpful information!! The time and effort you've put into your website is amazing!! Great job!! I envy that you can plan everything out in advance!! I have a general floor plan but I'm building as I go, it might not be the best way but that's how my brain works! LOL Plus, it seems I'm always waiting on a delivery of something!!
Learning all the little 8020 tricks has been frustrating and rewarding at the same time!! I've been learning a lot from Ken at OurKaraVan on YouTube, that guys amazing too!!
The most frustrating thing about 8020 is it seems like you almost have to invent everything you want to do!! I'm also using Series 1515 8020. What size piano hinge did you use on your cabinet doors?
 

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Discussion Starter · #11 ·
At this point I started to run some wire and framing the ceiling.Let the fun begin, Not!!
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Discussion Starter · #12 · (Edited)
After installing a few windows in the van the MaxxAir fan was a breeze to install. The only issue I had was I bought the wrong Lap Sealant, I didn't buy the self leveling stuff. It took about a week for it to arrive!! I did wash the van before putting on the correct Lap Sealant and the MaxxAir fan did not leak a drop!! So I think that worked out well in the long run, I know it should never leak!! You'll also notice in the pictures I added some aluminum strips to the top of the fan for a better seal when screwing them into the frame below. That fan is rock solid!!
A few install tips I learnt from watching YouTube fan installs is use one continuous bead of butyl tape around the whole fan, don't cut into small pieces and have your only seam in the back of the fan area. I would definitely build a frame to screw the fan into. I also bought the gasket for the install so you're installing it on a flat surface instead of adding layers of buytl tape.

I found this to be one of the best videos on installing the fan!!
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Wow you are making some serious progress. Until I get my van, hopefully by the end of this month, I look forward to post like yours!
 

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What size piano hinge did you use on your cabinet doors?
McMaster-Carr part # 1581A631 piano hinge without holes. 3" width x .90 thick with 1/4" pin and 1" knuckle length.

A flat SS washer must be installed between the hinge and 80/20 to compensate for the tapered legs of the 80/20.
 

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Nice! I'm also building my bench, bed platform, and kitchen unit out of 10 and 15 series. My kitchen cabinet is out of 10 series and I'm still figuring out how to attach door hinges on them. Welcome any ideas!
 

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Nice! I'm also building my bench, bed platform, and kitchen unit out of 10 and 15 series. My kitchen cabinet is out of 10 series and I'm still figuring out how to attach door hinges on them. Welcome any ideas!
You could use full length aluminum piano hinges. One leaf bolted to the 80/20 and the other leaf screwed or bolted to a wood block that is glued to door plywood.
 

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Discussion Starter · #20 · (Edited)
The next project was to install the flooring, since I'll be using this van for skiing a lot I wanted a rubber type floor so I used this stuff.

I didn't really feel like making cardboard templates for the whole van so I cut it a few inches wider than the widest part of the van and started measuring around the floor at the front of the van and cut out the seat area. Then I was able to fit it in and roll it out. I worked towards the back cutting it to fit. The edges won't be seen anyways but I was able to get it really close. I eventually bought a floor mat for the front that I put over the flooring I installed.
I installed this on a really hot day so I was able to cut it really easy with some scissors.



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