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I thought it was expansive too!! But I will say it's very good quality and I don't think I could've made one that good!! But if you can make it, I say go for it!! I also think that guy that sells the 3m insulation is also over priced big time but I did buy the roof mount brackets from him for like $50 each and they worked out well. I still felt like I was getting ripped off too!! Good Luck in your build!!
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Didn’t know he did brackets for the roof. Just bought some from DIY van today.

I had already ordered a plate of 1/4 aluminum from. Amazon, so I’ll try that first...


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2020 AWD Transit 250 MR
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Discussion Starter · #223 ·
Ordered a second Lagun table and mounted it in the back of the van.
I had to remove a panel to drill the holes to mount the Lagun table to.
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I clamped a scrap piece of wood to the panel and then drilled the holes so I wouldn't ruin the laminate.

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Holes came out nice.
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I fabricated a strip of aluminum to screw the Lagun plate to and I also attached it to the 80/20 for extra support.
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This is just a prototype table top. I'll make a bigger one.
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Discussion Starter · #224 ·
Added another Lagun mount today. I plan on having two table tops and 3 mounts.
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The slide in T nuts work great.
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The table can spin around into the cooking area.
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Lunch Slope side today!
 

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2020 350 AWD 148 HR CREW
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I received some laminate I ordered from Home Depot, ( Wilsonart 4 ft. x 8 ft. Laminate Sheet in High Line with Premium Linearity Finish-7970K183504896 - The Home Depot )

It was time to give laminating a try for the first time. You definitely need to wear a mask when you apply the glue. It's easy to do, you just put glue on the wood and laminate and wait 20 minutes. Then you put them together carefully because one they touch it's very hard to adjust it. On large pieces I used a few dowels to get the placement correct and then removed them. I also used a roller to help it stick. Once the glue is dried I used a router with a flush trim bit to trim it and then I did some sanding on the edges.

Here's the glue I used, Wilsonart 128 fl. oz. WA600 Consumer Brush/Roller Grade Contact Adhesive-WA-600OC1GAL - The Home Depot

It's a time consuming process but the end result isn't bad looking.

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Discussion Starter · #226 ·
I cut out my second prototype table. This one is bigger for the back of the van.
Both the tables come off the Lagun mount and become the platform for the bed. I have a third section the completes the bed platform, when not in use it goes in the coat cabinet on the bottom. Everything fits great!
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The table tops remove from the Lagun mounts and become the bed platform they fit perfectly on the 80/20 edge, it's really solid and the bed's really comfortable!
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2020 Ford Transit XLT AWD LR Wagon, 3.5 EcoBoost V6,
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There you go, teasing me again with that killer Dead quilt!!
 

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Our windows came with no instructions and it's a bit confusing on which way the trim goes. YOu have it where the labels are facing into the van. While some other people have it installed it the other way around with labels facing to wall of the van.

How thick of plywood did you use for the frame?

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. View attachment 139569 View attachment 139570 View attachment 139571 View attachment 139572 View attachment 139573 View attachment 139574
 

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2021 AWD 148" HR 3.5L EcoBoost Avalanche Grey
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The cabinet doors were a challenge to install, I had to order some smaller t-nuts and bolts and find a piano hinge that would work. My first set of doors warped slightly and the wife made me make new ones!! It was also a challenge installing a latch.
Any chance you have a link to the piano hinge that was the right size? Also, any tips on the latch install? I am planning a very similar cabinet design. Thanks!
 

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Discussion Starter · #230 ·
Our windows came with no instructions and it's a bit confusing on which way the trim goes. YOu have it where the labels are facing into the van. While some other people have it installed it the other way around with labels facing to wall of the van.

How thick of plywood did you use for the frame?
Hello, I used 3/4 plywood to make the frame. I've sprayed it a lot with water when I've washed the van and no leaks! After ski season I'll make the inside panels. Good luck on you build!
 

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Discussion Starter · #231 ·
Any chance you have a link to the piano hinge that was the right size? Also, any tips on the latch install? I am planning a very similar cabinet design. Thanks!
Hello, the hinges i used are from Home Depot, it's the standard hinge they stock. I'll try to get a picture to post. You'll need to buy a smaller tnuts and screws.
They're really easy to cut down to size, I used metal snips to cut the hinge and then a hacksaw to cut the metal tube. They work great!
 

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Any chance you have a link to the piano hinge that was the right size? Also, any tips on the latch install? I am planning a very similar cabinet design. Thanks!
I bought full length 2 1/2" aluminum piano hinges without holes from McMaster-Carr part Number 1581a611. Easy to cut to length wanted and add holes where you want them.

Doors are 15/32" plywood with a 3/4" square piece of wood glued to the plywood hinge edge for the hinge bolts. You must put a flat washer between the hinge leaf and the extrusion to compensate for the extrusion tapered legs. I used series 15 80/20.

For latches I used Southco M-63.

See second row first picture of door with hinge and latch:

Refrigerator | Orton Travel Transit (ortontransit.info)
 

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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!
Hi there,
We hope to make all our cabinets out of the 1” 8020 and I’m wondering if you had any trouble finding fasteners for this size? Where did you get your materials. THX!
 

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2020 350 AWD 148 HR CREW
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tnutz.com has reasonable pricing and shipping for fasteners. Also, 1/4" carriage bolts fit in the 10 series slots. You can cut angled aluminum to size for mounting brackets.
 

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Continued building the bed/ bench area out of 80/20, made the same mistake of having the 80/20 ends, end with an open piece of 80/20. I would later fix that on both the kitchen and bed area.
My first piece of wood would be added to the build. I went with 3/4 ply because I'll be attaching both the water heater and water pump to that wall plus running pex lines to the kitchen sink area. I put a few coats of mold & mildew resistant urethane on the wood.
This was my first time using rivet nut tool, I got it on Amazon and it's been very helpful. Amazon.com: WORKPRO 15" Hand Rivet Nut Setter Kit - 79-Piece High Leverage Rivet Nut Tool with Metric & SAE Mandrels and Nuts: Automotive
It was also my first time drilling holes into the 80/20, after I attached it to the van I couldn't believe how solid it was!!

I started using the panels that came with the van to attach to the walls to hold the insulation in place.
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VERY impressive. I hope I don’t go broke from making too many mistakes with the 8020! Still planning our layout and researching cheapest sources. I really like your wheel well covers. Where did you find them and how do they attach? Really enjoying your project!
 

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Discussion Starter · #236 ·
Hi there,
We hope to make all our cabinets out of the 1” 8020 and I’m wondering if you had any trouble finding fasteners for this size? Where did you get your materials. THX!
Hello, sorry I've been busy skiing all winter and haven't been watching this forum closely. I used 15 series 8020 for all my build but I'm sure you'll be able to find fasteners no problem, tnutz is a good place to get them.
Good luck on your build!!
 

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Discussion Starter · #237 ·
VERY impressive. I hope I don’t go broke from making too many mistakes with the 8020! Still planning our layout and researching cheapest sources. I really like your wheel well covers. Where did you find them and how do they attach? Really enjoying your project!
I found I didn't make that many mistakes the hardest part is actually figuring out what to order!! One mistake I made is not ordering enough fasteners, always order extra or you'll be waiting for them in the mail and that can set you back weeks!!
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I think you're talking about the black inside wheel covers, they came with the van. I think I have one left, if you want it you can have it. I can ship it to you if you pay the shipping. I'm located in the Tahoe area.

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I found I didn't make that many mistakes the hardest part is actually figuring out what to order!! One mistake I made is not ordering enough fasteners, always order extra or you'll be waiting for them in the mail and that can set you back weeks!!
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I think you're talking about the black inside wheel covers, they came with the van. I think I have one left, if you want it you can have it. I can ship it to you if you pay the shipping. I'm located in the Tahoe area.

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NICE!!! Very generous offer! I’m in Wisconsin. It probably doesn’t weigh much. Any guesses on cost of shipping?
 

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Discussion Starter · #239 ·
NICE!!! Very generous offer! I’m in Wisconsin. It probably doesn’t weigh much. Any guesses on cost of shipping?
Not sure but why don't you check how much from Ford and maybe they only sell it in a 2 pack? I'm guessing shipping will be around $25? Good luck
 

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Discussion Starter · #240 ·
As ski season is melting away and the weather's getting warmer I decided to do a little work on the van.
I still have a lot of small projects to complete my build but the good news is it's worked great during ski season!
I've got in 122 days skiing so far this season so I've been able to test out everything. I hope to hit around 140 days by the time Squaw/ Alpine and Mammoth close next month!
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Today I added some hanging hooks and it also has a small shelf.
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The hooks open and close so when you're not using them they retract.
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I also added another set in the back but this one doesn't have a small storage shelf.
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It was fun to start working on the van again! Can't wait to get it done!
 
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