So this is the build sheet for our Van we ordered and the planning sheet I presented Ed with. The roof design plans on my planning sheet were done by Orion (free) and we used their products for our roof rack/walkable solar panel build.

 

From Mid March to April the AM Auto Windows, Roof Skylight/Access Hatch, Maxxair Fan, Orion Roof Rack system and Walkable Solar Panels are installed. We chose the AM Auto Windows because they look the closest to factory passenger van windows. We installed them full length down both sides even though the front drivers side widows are not even cut through (shower box is there) just to maintain that look. The Orion Roof Rack system is REALLY Top Notch and they are great to deal with. We love the fit and finish and the overall look. LED Lights on all four sides of rack are wired into the 4 Upfitter switches in the cab. It was important that from the ground nothing appears higher than the sides of the rack for a clean, stealthy look. Hence the name "Ghost".

 

April into May Kilmat sound deadening, and Thinsulate Insulation installed,
Van Life Tech Caldera Floor System for Hydronic Floor Heating (part of the Roman Holiday System), installed. Ed Trayner of Interstate Custom Vans is a certified Van Life Tech installer.
Rough wall framing installed. All plywood is Marine Plywood.
Wiring roughed in

 

By Mid-May the Lonseal Marine Flooring was installed. It was done full length and width seamless. Much care had to be taken to mark where the Plex tubing was routed so as not to drive a nice stainless steel screw through it when mounting the equipment in the back and ruin the whole hydronic system. A bit nerve racking for Ed but worth it in the end

 

May into June, Electrical, Plumbing, Garmin SERV Control System, Heating and Air Conditioning system infrastructure is installed. One of the main reasons we chose Ed for our build is his excellent attention to detail in his system installs. Please note the small but telling detail of how Ed uses colored wire ties to match the color of the wires being bundled. Just one of the clues that he is a craftsman that takes pride in his work.
We insisted on Lithionics as they are as far as we know, the only Lithium Battery certified for vehicle use by UL. They are virtually bulletproof. Lithionics is your choice if ultimate safety is your main concern. You will pay for it but you do get what you pay for in this case. Ed worked closely with the techs at Lithionics to design a comprehensive 48 volt system that produces 1320 AH. Batteries get charged by 600 Watts of Walkable Maxeon Sunpower Cells, Factory second alternator and 30 amp shore power. The system is smart enough to always keep the chassis dual batteries fully charged. It also will auto start the engine if the house batteries drop below a certain amount and kick up to fast idle to charge them so to keep the 48 volt Cruise N Comfort Air Conditioner going.
Fresh water tank is 50 gallons with all the fittings through the top.

 

May into June, Continued,.... Electrical, Plumbing, Garmin SERV Control System, Onboard Air Compressor, Heating and Air Conditioning system infrastructure is installed. One of the main reasons we chose Ed for our build is his excellent attention to detail in his system installs.

 

May into June the Ceiling Panels were upholstered in marine vinyl in a style to mimic the Classic Riva Aquarama.
Installed with construction adhesive.

 

June into July the front over cab bulkhead fabricated out of 3/4 Sapele Mahogany veneered marine plywood and trimmed with solid Mahogany. Van Made Gear Insulated Cab Curtain Divider test installed.

 

June into July continued.. Happy Jac bed lift bulkheads fabricated out of 3/4 Sapele Mahogany veneered marine plywood.

 

July Mahogany Trim Pieces fabricated.

 

July Continued... Solid Mahogany Center Strip with classic design LED Marine Cabin Lights installed.
Lights are controlled by Garmin SERV System, are dimmable and can be switched from White to night vision Red or off locally on each unit. Solid Mahogany ceiling trim installed You can see how well Ed matched the actual ceiling with my design mock-up. We are very happy with the results!

 

July into August As our design is a hybrid Wood/8020 build it was time for Ed to start playing with the rear seating/dining area 8020 framing. We specced Black Anodized 8020 with all Stainless Steel fasteners.
Happy Jac elevator bed mechanism and bed frame installed. The underside of the bed will be finished exactly like the ceiling over the bed in the same marine vinyl and Mahogany with the same classic marine cabin lights.

 

August Shower Box fabricated. Custom Stainless Steel Shower Pan, Marine Plywood walls treated with Red Guard Waterproofing System. Shower will drain into an under-mounted 25 gallon grey water tank.
On the other side the kitchen sink will have its own under-mounted 25 gallon grey water tank.
Laveo Dry Flush toilet allows us to eliminate a Black water tank.

 

August continued... Glass Shower and Backsplash Tiles installed with Ardex WA High Performance 100% Solids Epoxy Adhesive, yet to be grouted with Ardex WA High Performance 100% Solids Epoxy Grout
If we had to do it over again we would not have chosen the glass tiles as they are a bitch to cut and drill without shattering. It gave Ed fits but he pulled it off in the end. The glass tiles look insanely good (so much depth) so we are happy about that but anyone tempted to use them be forewarned,...they are a nightmare to work with. Stick with ceramic tile or FRP.

 

Absolutely fantastic design and work! Two questions: total budget? and total weight? Just curious....

 

Total cost with Van will be around 250K. We have yet to weigh it, we will when it is done but we paid pretty close attention to weight distribution keeping it evenly distributed and low. For instance there is no air conditioner on the roof, it is mounted almost over the rear axle and mounted to the floor. 50 gallon fresh water is behind it and centered. Lithionics batteries are mounted behind each rear wheel. The ceiling is vinyl over 1/4 marine ply not heavy wood. The chassis is the most heavy duty they make with the heavy duty axles front and rear with the duallies, towing package and forged aluminum wheels so almost whatever we do will be within its weight rating.

 

 

As Lori and I (& Moose) live on Long Island (New York) and Interstate Custom Vans is located 4 hours away in Tyngsborough Massachusetts we don't get many chances to see the progress in person. Monday August 18, we did and these shots are from then. We are VERY happy with the progress.

 

As Lori and I (& Moose) live on Long Island (New York) and Interstate Custom Vans is located 4 hours away in Tyngsborough Massachusetts we don't get many chances to see the progress in person. Monday August 18, we did and these shots are from then. We are VERY happy with the progress. Lori got to try out the Prime Design No-Drill Black Anodized Rear Door Ladder and the Walkable Solar Panels on the Orion Roof Deck! Note the Black Stainless Steel Roof Grab Rail. It makes a big difference in getting on and off the roof. Roof deck is also accessible from inside using the roof hatch/skylight.

 

Future work - This mock-up will be the basic design of the shower box door. Marine cleats are to be used as coat/hat hooks.
This is how I communicate with Ed as to what we are imagining. I will do a Photoshop mock-up and Ed takes it from there and creates the reality.

 

WOW

 

Stunning. What is the large box in front of the rear doors?

 

50 Gallon Fresh Water Tank. It is boxed over with wood and auto carpet so Lithionics External BMS can be mounted to front facing side of it and we can store stuff on top of it. Rear seating area and under seat storage is framed out in Black 8020 over it. Thank you for the compliment!

 

Everyone else can comment on the build. Nice to see a real dog. I don't need heating but I absolutely need AC to keep a Malamute happy. For that reason, I got the OEM rear AC unit for my cargo and am currently trying to figure out a solution for shore power and battery.

 

2024 Ford Transit Touring Van "Ghost" Build Progress
Marine Vinyl upholstered panels in Classic "Riva Aquarama" colors to match ceiling panels have been fitted under "Happy Jac" Elevator Bed.
Teak & Holly Strip Deck Flooring fabricated for raised floor in front of rear seating/dining area.
Cruise N Comfort Air Conditioner ducting test fitted.
Rear seating/dining area woodwork being test fitted.

 

2024 Ford Transit HD350 "Ghost" Touring Van Build Progress;
Cabinetry for Isotherm DR130 Marine Refrigerator is being fabricated from 3/4 Marine Plywood with African Sapele Mahogany veneer. This will be topped by Hickory and Mahogany Butcher Block countertop. Appliance garage will be above of countertop Breville Microwave. To the right side of the refrigerator will be a pull out pantry drawer.
Sample drawer front is being mocked up out of 3/4 Marine Plywood with African Sapele Mahogany veneer and framed with solid Mahogany edge pieces. The drawers themselves will be full height solid 5/8 mahogany that will be dovetailed together. Latch is Stainless Steel Marine cabinet latch.
We chose the Isotherm marine refrigerator because it runs on DC power and can handle being in constant motion and not always level.
You can also see the raised Teak & Holly step which will hinge up for storage underneath.

 

Fantastic build! Great job on the design and Ed's execution! Love how stealth it looks, and having a full walkable deck is rad also!

 

Thank you!