[Ranger Robin]

Leviathan
noun

• a giant sea monster with roots in pre-biblical mythologies
• any huge marine animal, as the whale
• anything of immense size and power

A large gray van affectionately known as ‘Levi'

A Little History
After 21 years camping and traveling in my Four Wheel Pop Up Hawk Camper on a Ford F150 4X4 pickup I have decided to opt for less off road ability and go with something roomier with more of the comforts of home. I wanted more space for traveling solo and sometimes with another person and my dog. And maybe, the cat……While set up of the FWC was really easy, I wanted to skip the popping up part and all the bed assembly and disassembly and gear/dog stuff rearrangement that that entailed. How did the dog accumulate so much stuff??

Purpose and Planned Use
A three season van as a comfortable base for dispersed camping in remote locations, occasional campground or city use. Trips commonly three to 30 days, sometimes longer. Capable AWD for moderate dirt road travel & adventures. Park Ranger's Motto: "five minutes of walking can save five hours of digging'......
Larger solar array as I tend to reach an area and stay a few days. I rarely use shore power (I worked in campgrounds for 30+ years so generally avoid them now).
I hardly use an inverter, but WTF why not, I’m trying to create more of a camper/RV thing for more creature comforts in this next phase.

Basic stats

• 2022 148" Extended Body HR T250 CARGO AWD (R3U body code)
• Avalanche Grey
• 3.5L EcoBoost V6, 3.73 HD axle
• Most items on the Adventure Package: dual AGMs, all available electronics & cameras etc. HIDs, push button start, 12” screen, Leather 10 way seats w/aftermarket swivels, HD tow package & controller.

Design Principles

• Comfortable base for solo adult traveler (sometimes two) and a 40 pound yellow adventure dog. And maybe the cat …..
• Mind build weight and maintain crash safety features wherever possible.
• Not stealth, its my big ass, gray camper
• Colorful aesthetic vs cabin/rustic/woodsy look

Must Have Features

• Comfortable bed with NO daily assembly/disassembly, ok - I will make the bed by pulling up & fluffing out the down comforter but that's it.
• Waterless dry toilet (aka Natures Head Composting Toilet)
• Reliable 12VDC refrigerator, tired of the old 3 way PITA in the FWC.
• Propane for cooking & heat
• Comfy place to sit with legs propped up - see adjustable base bed
• Space to entertain 3-4 adults in bad weather
• Westfalia style open concept for 'dog floor space'
• Good insulation & ventilation w/o overthinking this, I prefer warmer climates
• Garage style design w/storage for my big ass eBike &/or regular bike
• Removable cubbies/storage to accommodate scuba tanks & wet scuba equipment
• Rear door shower/hose off area
• Overland Systems 180 degree batwing awning
• Integrated travel safe for travel across our southern border (and maybe the northern border too...watch those polite Canadians......)
• Viair Compressor, Maxx Tracks, recovery gear, prolly no winch

Layout & Materials Summary

• Thinsulate insulation & Kilmat type sound deadening
• Propex HS2000 heater, still have my simple Mr. Heater Buddy and it was overkill
• U/M RV Propane tank on passenger side w/ext connector for BBQ outside
• MaxxAir fan almost most forward, solar aft of that, minimal roof rack, simple fairing
• Driver’s side VWD openable window and a CRL awning window @ bed
• Passenger side: full glass, all openable exc. slider door - again, the dog's needs for views..........she won't sit up front no matter what type of coaxing.
• Galley behind driver w/raised up 130L 2 way fridge, oven/cooktop combo, sink with faucet, pull out handle & soap dispenser
• 36” Transit bench seat against the bed serves as dog bench/bed for underway and a step up into the bed (Four Wheel Camper style)
• E-W adjustable bed - full size, garage underneath
• 80/20 extrusion construction
• Bug Wall Screens side & rear
• LONSEAL Linen Artichoke flooring on 1/2” marine ply & mini cell per Far Out Ride
• Upholstered walls in grey marathon tweed or similar sunbrella with raptor liner sprayed on lower rear garage walls
• Two Amazing Auto swivels on 10 way power seats
• Table(s) with Lagun mount or convertible table TBD

Electrical

• 12VDC house system based on Explorist.life designed plan
• 400 A Hrs Battleborn batteries (4x100)
• 740W Solar from two Solaria 370W Solar panels in series
• Victron MPPT 150/70Tr charge controller
• Victron 3000W charger/inverter with digital controller
• Sterling BB1260 DC-DC Charger (60 Amp)
• Simarine PICO Blue monitoring & display
• 30A Furrion Shorepower inlet

Plumbing

• 20-40 gal fresh water tank TBD, inside mount, w/H2O pump etc
• 20 gal grey/yellow tank, planned under mount or may go simpler
• Isotemp Spa 25 Water Heater mounted under van
• Nature’s head dry toilet, TBD plumbing of P tank to gray/yellow

Kitchen

• Isotherm Elegance 130L AC/DC fridge
• Dometic R31 Oven/3 Burner propane stove
• Microwave TBDecided
• Modena brand U/M Stainless sink 15”X17”
• Appaso brand Kitchen faucet with pull out sprayer
• Propane BBQ for outside cooking

Other Items

• 12 VDC under mount A/C - ProAir unit - cool dog in van during grocery run, not thinking this is for running on hot days/evenings
• Adjustable Zero G bed unit
• Lagun Table w/mount or free standing adjustable as in FarOutRide
• Is the cat coming or not……
• I'm taking my time with the multitude of necessary decisions and the crazy workload needed to accomplish this project. I'm so grateful for all of the folks who have gone before and posted their build threads. So many helpful tips and experiences to draw from. I won't redo what as been effectively covered but will show what might be helpful to others (mostly my epic mess ups). I've barely started and after redoing almost every project two or more times, I'm taking a break and posting where I'm at.

 

[Ranger Robin]

Bought the van at the end of May from Ed Bowers - Crew Van Man. Flew out to Kansas City and drove it home. Highly recommend using @CrewVanManInfo for getting the van you want. I did a trip review for the first van I got from Ed. Bought my van @ Gary Crossley thru CVM - Ed Bowers - a...

Started work on Father's Day. My Dad loves to tinker with vintage motorcycles and any type of old car you can think of. He is always up to help me with my latest crazy idea/project. I showed up on Dad Day with a major first van project and while he was excited to help out, he was in disbelief that I was about to cut giant holes in my brand new van.

The Start:

 

[T town]

Do your build in your own sequence but I would leave solar for later. You might find with 400 amp hours of battery and alternator charging that you just don’t need it.
You do have a pretty big fridge, mine is a 75L, and I don’t know if you are only going to heat water while underway. Try it for a little bit without solar, you might find you never miss it.

 

[T town]

Oops, well it looks like you may have done the work already.

 

[Ranger Robin]

Challenge #1 - fit the HR van into my dad's driveway!! He didnt want to trench whenever he installed the automatic gate - so he jerry rigged whatever you call this thing he made. 🤣🤣 I love to give him **IT ...

 

[Ranger Robin]

Many have posted their window process, not much to add here.

I ordered it with rear door and slider fixed Ford windows. Initially I was doing two "pill type awning CRL windows in the back at the bed area. But after seeing the good views had by @gregoryx and @Mauronic AND deciding the dog would love a window at her mid-rear bench seat, I added full passenger side glue in windows from VWD. Did will call pickup while heading up I-395 on the windows and saved a ton of freight charges. VWD has the most excellent customer service. There was some dried up primer and some other small errors and they always made it right as soon as I brought it to their attention. Check your VWD primer carefully before cutting holes in your van. OR buy a sealed metal bottle of primer (from VWD or Napa or Amazon) - it lasts longer that way.

I thought a slider window & mid-van window would look dumb w/o the rear section window so I went for the full length passenger style window effect. Came out nicely if I do say so myself!!

Followed the VWD videos. Got the high ratio hand pump for the urethane on amazon and "V" notched the plastic tube end as directed in the VWD instructions videos. No leaks in three urethane installed windows. Wish I could say the same for the little CRL pill window!!! That took a few reinstallation attempts at sealing a big leak and I ended up using some butyl tape under the inside trim piece to stop the leak. I recommend using some hex head tiny screws to attach the clamp in trim ring to the window instead of the tiny **** phillips head screws they provide. For sure, pre-drill the pilot holes - their instructional video makes that sound optional. Just do it before installing a CRL clamp in.

Cut the first window with my jig saw from inside the van. Big mistake - the not-so- flat surface and obstacles made the saw blade track everywhere off course. Next three windows used a punch to mark the widow "lines" from inside. Traced punch marks with sharpie on outside and found this worked much better. My advice - cut w/jigsaw from outside! Gather & control those metal shavings, they go everywhere.

I felt like a pro by the fourth window cut.....luckily the glue in windows have large tolerance for boo boos.

Sorry not many in progress pictures, I was doing the work (props to those filming and IG'ing shorts and all) and well, my Pops doesn't do the iPhone photography very well.....😉

Let the cutting begin:

 

[Ranger Robin]

Oops, well it looks like you may have done the work already.

Ya, sorry and thanks but that ship sailed. 🤣

Happy with the plan, had a long time for planning whilst waiting for the van. I wouldn't do it w/o solar and will be installing Undermount A/C so all charging methods welcome as I tend to stay in place for longer periods rather than drive everyday.

 

[Ranger Robin]

Jumping ahead to last week - here is sneak peek at where the van is now. I'm behind on starting the thread and honestly I have wavered on even posting anything as I have to redo every **** thing twice. It makes me wonder if posting anything would ever be helpful to anyone. Maybe it will serve here as a guide on what not to do.

Had a multi week trip to Mammoth Lakes and Truckee planned so rushed to get the van into "metal tent" stage for the mostly campground bound camping trip with friends. Might have had some adult beverages at Raley's and Truckee Brewing but alas, no Miracle Whip sightings!!!

Highly recommend using your "metal tent" in the early stages to test out your layout and ideas. I came upon many ideas for my 'to do' list despite having over 20 years FWCamper experience to base this build off of.

Very happy that my skittish doggo loves her bench seat & windows.......

Ignore the massive mattress, I literally finished the bed framing a'la @maia and @VanMode on Friday night and had to leave early Sat morning so I just grabbed my spare bed mega-mattress from the house. Despite the 12" mattress putting me into the rafters, at 5' 10" I was fine sleeping across the transverse bed and was able to sit up on the bed just fine. I want cabinets at the feet and have the undermount A/C blower unit to mount at roof height so the bed WILL be lower....eventually....someday......

 

[Vanaroo]

It makes me wonder if posting anything would ever be helpful to anyone.

There were so many things on the build list in your first post that had me thinking: "Oh, I am looking forward to seeing how RR does that and what it looks like in place." I can't be the only one. So thanks for what you've shown so far, and I hope you keep on posting your build.

 

[Ranger Robin]

Installed the VC Rocker Guards pretty early on.

After using them camping now and for the 1349 times I get into and out of the van each build day, I have to say I'm super happy with them. Low profile, serve multiple purposes and they look nice. Haven't tried rock sliding on them yet, so don't ask.

Info here: Installed some Van Compass Rocker Guards & question...

 

[Ranger Robin]

Tire upgrade.

I'm kind of ghetto sometimes. I'm ok for now with my stock steelies. I hate the center cap things but I ordered some 3D printed covers from Hein. Yet to be installed.

I put some Falken Wildpeak AT3W LT 245/75/R16 's on right before the camping trip. Did 1200 miles - they rode great, tracked well. MPG def lower with partial build, solar, jerry-rigged fairing and larger tires. Averaged 14-15 MPG on the unmodified computer, so maybe 4% higher than that with this larger tire size. I have front wheel well liners and they rub slightly when turning. The ends of the liners aren't attached very well because of the rocker guards or lack of OEM trim due to rocker guards. See that post for deets. Will roll/pound the pinch welds and heat & reattach the plastic liners better when I get the time then spray the painted exposed ends. I have a long list for a raptor liner spray project coming up.

Discount Tire busted up two of the brand new Conti OEM tire beads when dismounting them (sorry deleted the pics) ....USE LUBE people. Somehow those two tires with busted bead were on the bottom of the stack in the back of my van when I drove home....wasn't happy upon unloading. I called the shop back and spoke to my service advisor and he told me 'it happens nothing they can do'......I have had hundreds of tires dismounted, patched and remounted and never have seen this busted bead thing. I know that doesn't mean it doesn't happen. So, five minutes on google confirmed my experiences. I called the next day and second Discount guy told me that 'sometimes it happens, sorry nothing we can do'.

So I loaded up the two busted tires & went to the store and asked to talk to the manager. He took a quick look & said that isn't right. And he made it right. Have to shout out to Discount Tire, Sport Arena, San Diego for doing the right thing. Customers, insist on talking to someone in charge. The guys work their butts off in there and they are always really helpful but don't accept what the tire jockey might tell you first thing.

So I have three (instead of five) like new OEM Conti Tires for sale at a great price if anyone is interested.

 

[CrewVanManInfo]

Glad everything has worked out on your Transit upfitting. You are one of many who came to Kansas City to get their van and went on to make it like you wanted it and will be able to enjoy it for a long time. That is my main purpose of doing this gig along with making a lot of people reach their dreams with getting a van.

 

[Van Gogh]

• Adjustable Zero G bed unit

I knew I wasn't the only one. Once you get used to an adjustable bed w/remote, zero g, and other niceties, there's no going back. Good choice. They also make under-bed storage a cinch, especially the top half (my battery bank/power system is under the bottom half). Just press the remote and suddenly you have nearly open access to all that storage space.

I debated a lot over mattresses, and have found a 10" hybrid to offer excellent comfort + support (no middle sag). In my twenties I used a firm Sealy Posturepedic for a good 7 years and loved it. As I got older I kept spending more and more on mattresses, getting thicker (12-16") and softer ones, but I was never quite pleased with them. Turns out I just prefer the firmness that 10" and similar mattresses offer. Foam always sags eventually, but hybrids seem like an excellent compromise. They don't work quite as well with adjustable beds (need to be sitting upright on the bed when lifting to "couch mode" to prevent folding at the bend), but it's worth it for sleep. On a recent 8 week trip in the van, even at the end of the trip there was no noticeable sag in the center. With the pricey all memory foam one I bought years ago (and returned to Mattress Firm within 30 days) it had started to sag after 2-3 weeks.

Cheers.

 

[Ranger Robin]

I knew I wasn't the only one. Once you get used to an adjustable bed w/remote, zero g, and other niceties, there's no going back. Good choice. They also make under-bed storage a cinch, especially the top half (my battery bank/power system is under the bottom half). Just press the remote and suddenly you have nearly open access to all that storage space.

I debated a lot over mattresses, and have found a 10" hybrid to offer excellent comfort + support (no middle sag). In my twenties I used a firm Sealy Posturepedic for a good 7 years and loved it. As I got older I kept spending more and more on mattresses, getting thicker (12-16") and softer ones, but I was never quite pleased with them. Turns out I just prefer the firmness that 10" and similar mattresses offer. Foam always sags eventually, but hybrids seem like an excellent compromise. They don't work quite as well with adjustable beds (need to be sitting upright on the bed when lifting to "couch mode" to prevent folding at the bend), but it's worth it for sleep. On a recent 8 week trip in the van, even at the end of the trip there was no noticeable sag in the center. With the pricey all memory foam one I bought years ago (and returned to Mattress Firm within 30 days) it had started to sag after 2-3 weeks.

Cheers.

I like it so far. I like @gregoryx' adjustable height bed with linear actuators to also 'sit up' but I decided to just try a low profile platform adjustable after seeing it on Humble Road. I also liked that I could pretty easily get it up and out of the way as my electrical system will be in the dead space under the fridge cabinet at the head of the bed in front of the wheel well.

But even with a 'low profile' designation, its almost 3" thick. I'm still pondering of there's a way to frame 80.20 around the outside of it to support it. Right now its sitting on top of 80/20 as I needed something to go camping and with 80/20 I can rearrange it all if I think of a way. It doesn't work very well with that type of spring mattress and with the reduced height.

I'm one of the odd ones that can sleep on any old brick as long as I add a memory foam topper so will try one of the thin 4" Ikea mattresses with a topper I think. Cheap combo. I sleep great on a Tuft & Needle at home and thought about putting a new one on my bed at home and trying to cut down the thickness my old one to fit but it seems like spending too much. I'm fine chopping corners off but doing a longitudinal flat cut across the whole short queen doesn't seem easy.

 

[dhagberg]

Love it - hopefully have a gray leviathan on the way too…
Any chance you could send a link to the solar panels you fit on there? I’m thinking we will want a similar roof layout on our extended.

 

[Ranger Robin]

Other early build things:
Limitless Vans rear tire rack. "Scored" off CL for $100. I saw that ad and thought oh its stolen for sure. I talked to the guy and he seemed legit but it was all the way up in Carlsbad thru hellish north county traffic. Then a couple days later I had to go to Carlsbad for a meeting so made arrangements to swing by and take a look at it. It was boxed with his name and address on it but the rack was incomplete. It needed a bunch of hardware and the actual thing the tire mounts on (shown in this pic)

So I called Limitless Vans and even though they don't sell these to the public anymore (only install them on their builds) they agreed to help me cobble together the missing parts. $600 later I have a rack. The top bracket that mounts inside the door (not on the hinge) broke right before I was to leave on the camping trip causing much concern (was an original piece) but they shipped out their updated version bracket which is much sturdier.

I'm probably the sole reason they will never sell to the public again but they have't seemed to have blocked my number yet. Kudos to Limitless Vans - another business doing good by someone who they really wouldn't normally be troubled with. Their builds are beautiful BTW in case you want a pro builder: https://www.youtube.com/c/LimitlessVan

I have a steep, narrow driveway and at mid-build she clears it just fine. Or does he clear it just fine? Not sure if Levi is male or female just yet, maybe its a "they".

Anyhow, new tires on a new black rim picked up with the van from Crew Van Man and we are in business. I got the rack despite concerns over door stability/reports of doors tearing. Those issues seem to be on older vans. (let's hope) I wanted to clear some space underneath for the undermount air conditioner, propane tank, Isotherm water heater and a gray tank.

Now that I have the larger tire mounted, I'm wondering if I should lower the tire mount so the tire is lower and almost touching the step. Even a few inches lower helps a lot to reduce the torque on the rack and those brackets when bumping along the road. The mounting plate is totally adjustable - the rack is like a large aluminum molle panel.

 

[Ranger Robin]

Love it - hopefully have a gray leviathan on the way too…
Any chance you could send a link to the solar panels you fit on there? I’m thinking we will want a similar roof layout on our extended.

This is the panel I selected: https://static1.squarespace.com/sta...36505/Datasheet_PowerXT_Resi-370PD_Rev_04.pdf

This is the vendor: https://tandem-solar-systems.com - they do will call and I was prepared to go pick them up in San Diego but they brought them to my house for free. Freight was a lot so that made a big difference. I think they are in northern LA and SD Counties as far as warehouses. I paid $707 out the door for both panels w/tax and no freight.

Let me see if I have enough pictures to post a write up on my rack installation. The dog got skunked this morning at 0600 and the skunk has holed up under my van in the planter on the neighbor's side of my driveway. 🤬 I'm not feeling like much will happen van-wise today, just sitting down with coffee after a morning of dog bathing and trying to get the spray smell out of the house. 🤬🤬 its excruciating with a full strength spray - you think this #*&! dog would learn, it's about the fourth time she has tried eating a skunk.

 

[JackHubbs]

Look great. Except for the color, I went abis grey, and the propane your lode out looks much like mine. Only have the one, passenger, swivel from AA. Best of luck with it. And great name by the way.

 

[Ranger Robin]

Weather Guard Roof Rack & Solar panels
I used Weatherguard Roof Racks (I said ghetto, I wasn't joking wait til you see my rattle can version #1). I liked the versatility and low profile system. And it was a low $$ investment if I decide later to buy a full on roof rack. I like the low profile rack systems from AVC, Unaka and Hein's options if I were going that route and those seemed like I could make them work with my larger solar panels but not my preferred awning so I tried a WG system after seeing someone else's install.

My 370 W Solaria solar panels: https://static1.squarespace.com/sta...36505/Datasheet_PowerXT_Resi-370PD_Rev_04.pdf
They are basically 64" long and 44" wide and 1.5" thick.

Before you rush out to find a Weatherguard system, know that Weather guard support for using their products on your camper van - SUCKS. They will come right out and tell you NOT to use or modify their products for your camper van. They really want everything to be installed by pro-upfitters on commercial work type vans. Not on your dream camper. Just be forewarned. Their stuff is well made and cheap but they are mired in the past. By sheer luck I was able to track down the last necessary parts from a re-seller on eBay to make my rack work because some Weatherguard racks come with all the pieces you need to attach the feet to the channels and some do not. Mine did not. Weatherguard won't help you and honestly Lowes was lost. Buyer beware is all I'm saying, you'll get much better service from companies catering to DIY van builders.

I got the weather guard items from Lowes special order but it looks like they aren't carrying it any longer.

• Weatherguard Mounting Channel Kit 148" WB and 148" EXT WB Transit: Van Accessories
• Weatherguard Universal Roof Mounting Kit Model 2510F : Weather Guard Roof Rack Mounting Kit, Universal Roof-Top - 2510F (can't even find this on WG site, know nothing about this vendor)
• Weatherguard Van Rack Hardware Kit 70706 also called Van Rack Field Service Kit - Weather Guard 70706 Van Rack Hardware Kit - Factory Sealed Package | eBay Found this on eBay for $25 with shipping. Its about $7 in parts and I found another vendor selling it for $9 but shipping was $40 so Went with eBay.

Like every good DIY van builder, I found the system/idea from a gal who posted their set up on fb. I will include her photos because they are better than mine.

If you mount them like she did, you will have a super low profile set up. Like she mentions, at the outer edge of the van its 5" tall. In the center you have about +1/2" clearance between your van roof and the bottom of the 80/20 cross bar. Super low profile but still allowing airflow under the panels for ventilation.

My rack version 2.0 is a little higher than this set up so the awning can attach on one side. I'm happy with it now and got the awning I wanted. If you're doing no awning or maybe something traditional like a Fiamma type I'd say go with an AVC, Unaka or Hein Roof Rack system with these larger size solar panels.

Or yes, use Orton's system and use one big panel and attach it directly to the roof, simple and easy.

Only overhead shot I have of Levi rack V 2.0

 

[Mauronic]

I ordered it with rear door and slider fixed Ford windows. Initially I was doing two "pill type awning CRL windows in the back at the bed area. But after seeing the good views had by @gregoryx and @Mauronic AND deciding the dog would love a window at her mid-rear bench seat, I added full passenger side glue in windows from VWD.

Great job!

Installed the VC Rocker Guards pretty early on.

Those really make a difference? I guess you added some bigger tires. What am I saying, I don't have the budget for those anyway.

I put some Falken Wildpeak AT3W LT 245/75/R16 's on right before the camping trip.

Oooh nice. I don't know what I was thinking when I replaced my OEM tires with questionably better and just as ugly other tires.