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My Adventure/Camper/ToyHauler/Conversion

72127 Views 82 Replies 32 Participants Last post by  driley
Purchased November 2014
Long Wheelbase---Extended Body---High Roof---2500 (3/4 ton) Power Stroke Diesel
6 speed automatic that can be shifted manually.
Power windows---Power locks--AC--Remote key entry--Cruise--Intermittent Wipers---Tilt and Telescoping Steering Wheel
Radio (nothing fancy)----complete tow package with reciever, trailer brake controller and a Tow Haul mode in the transmission.



Here is the finished product ------but how did I get there---read on.
Simple camper in front------toy hauler in rear.













I didn't order my van---found one on the lot that had pretty much what I wanted. One main priority besides cruise control was the factory tow package which includes a brake controller---also has 2 pluts at the rear---one is the 7 pin w/brake---and the other is a flat 4 connector.





With 15' of cargo I started my build------I will build a wall about 7'6" from the rear and will haul my dualsport motorcycles in there-----along with gear and all the dirty stuff.





The cargo area is 14' long------the back 8' will be for my bikes and I'll build a wall with a door to isolate the toy area.
The front 6' will be my camping and sleeping area. It will be comfy---but I will not put in a toilet, fridge, micro wave or shower.
I will be keeping it simple---but want a couch which makes into a bed very quickly in there.
I'm building this cabinet to go in the rear for riding gear and such.
I used 3/4" plywood---screwed everything together with sheet rock screws---but used wood glue also---the glue
makes it a lot stronger.














I got the steel part of the wall done-----I made it out of 1 5/8" uni-strut and welded the joints with my mig welder.
The Sides I bolted to the wall using 8mm bolts and fender washers. I made sure and used locking nuts so they don't work loose.
The 16" space in the middle will be a door. This will make easy access to things in the rear portion of the van.







The door fit absolutely perfect.
I used 2 magnets to hold the door closed---they are to weak---I'll have to do something else.
I used 1/2" plywood here---didn't need 3/4" and didn't want to use anything to thin as I may want to fasten
some things to the wall---maybe a cabinet ?????






A view from the rear----I'm pretty much done back here.
Maybe some paint on the back of the wall---a paper towel holder for sure.
A place to strap up my ramps---maybe strap them to the roof ????
Maybe a little easy to get to storage rack for WD-40, change lube--stuff like that.













Things are going well and fast-----this part here I was just bumfuzzled to what to do.
All of a sudden a lite went off in my head and I got my wire welder out and cut up some uni-strut and my combo couch and bed is in the making.
Most of this strut is 1 5/8".








More to come on the build.
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Enjoyed your trip report. We were in the Davis mountains many years ago and enjoyed a Star Party at the Observatory. Not sure if they do that anymore. Please drop by if you are ever out near Hood River, OR.

-Hein
I wish I could say I have lots to say.
But the van and the camper conversion I did worked out perfect.
Don't think I'll change anything. I just love it.
Awesome roadtrip. Really enjoyed your story and photos!
Enjoyed your trip report. We were in the Davis mountains many years ago and enjoyed a Star Party at the Observatory. Not sure if they do that anymore. Please drop by if you are ever out near Hood River, OR.

-Hein
Thanks for the offer---------been to Oregon a few times----really nice country.
Be close this year----Idaho, Nevada, Utah and Montana are on my radar again this year.

Awesome roadtrip. Really enjoyed your story and photos!
So glad you enjoyed Brad.

Mark
Hey Big Dog/Mark,

Elmotoloco from that other forum. Just had a quick question. Unlike you I do plan on living in the van. Going to take a year or two and travel the Americas with my lady. I am planning on picking up the extended/tall as well but my design was based on dimensions I could find prior to the van being available. I plan on putting the bikes in the "garage" ass first. Do you think the dimensions would allow for the design I show below?

Berkeley





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Hey Big Dog/Mark,

Elmotoloco from that other forum. Just had a quick question. Unlike you I do plan on living in the van. Going to take a year or two and travel the Americas with my lady. I am planning on picking up the extended/tall as well but my design was based on dimensions I could find prior to the van being available. I plan on putting the bikes in the "garage" ass first. Do you think the dimensions would allow for the design I show below?
]
Hi Elmotoloco,


I have no idea if your design will fit the dimensions------you'll have to figure that out on your own.

It' not easy putting bikes in the van forward because it's so high--------you would need 3-4 helpers to put it in backwards. Going forward I can just barely do it by myself with the aid of engine power----and 2 ramps-------one for the bike and one for me to walk up with. You'd never do it by yourself with one narrow ramp----the bike will get to high. You will regret trying to do the bikes backwards.
That's a pain with a low open trailer.

If you are going to live in it----------I think you better for sure get the tallest and longest.

Mark
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Agreed on the big and long. Sorry I was not clear in my question. I was wondering about room to put a bed over the seat but behind the handle bars on a dirt bike . Current bikes are a 610 and crf150. I just sold my f350 crew cab truck that had an 8 inch lift and 38inch tires. So the van even backwards looks so easy to me :) I use a tri-fold 84" ramp.

Also just wanted to say hi. You, and Gaspipe have been inspirations to me. I also count Fishfund as a friend.

Take care,

Berkeley
Hey Big Dog/Mark,

Elmotoloco from that other forum. Just had a quick question. Unlike you I do plan on living in the van. Going to take a year or two and travel the Americas with my lady. I am planning on picking up the extended/tall as well but my design was based on dimensions I could find prior to the van being available. I plan on putting the bikes in the "garage" ass first. Do you think the dimensions would allow for the design I show below?

Berkeley






Nice Cad drawings. What software are you using. I also like the fact that you leave the bathroom available when you are sleeping. I would need it :)
May I inquire as to how you mounted your wheel chocks? It looks like you've got them on a piece of plywood. Is the plywood attached to the van?
I just got my van and wheel chocks and additional passenger seats are the first thing i'm looking to add so I can start hauling bikes with it. I like the idea of mounting the chocks on plywood, especially while i'm figuring out where to place the chocks.
Also you mentioned you could only fit 2 bikes. Is there simply not enough width for a 3rd? Seems like it would be possible to slide a third in there, perhaps backwards.. But I haven't tried yet.

Thanks!
May I inquire as to how you mounted your wheel chocks? It looks like you've got them on a piece of plywood. Is the plywood attached to the van?
I just got my van and wheel chocks and additional passenger seats are the first thing i'm looking to add so I can start hauling bikes with it. I like the idea of mounting the chocks on plywood, especially while i'm figuring out where to place the chocks.
Also you mentioned you could only fit 2 bikes. Is there simply not enough width for a 3rd? Seems like it would be possible to slide a third in there, perhaps backwards.. But I haven't tried yet.

Thanks!
Yes I've got them bolted to a piece of 3/4" plywood that is not fastened at all. The plywood is up against the 1 1/2" uni-strut that is the framework of the wall-----so it's not going anywhere. And if I need to haul something else in the van the plywood and chocks (ATK bike shoes) just comes right out.

As far as the 3rd bike-------I've never tried it----------but from past experience on trailers I bet a 3rd one would go---but like you suggested it would definitely have to go backwards.
Also small bikes would help the 3 bike situation. As in dirt bikes---or small dualsports.

I've got some big tanks and saddlebag racks on my bikes---so this may not work for me if I tried it. But don't know for sure ????

I had this same piece of plywood and chocks in my old sprinter--it was an 06 and was not as wide as the transit. 2 bikes barely fit---and i had to tie them so they didn't sway and damage the sides of the sprinter.

BigDog
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Washing the Transit

Finally found out the first thing I don't like about my Transit.

Washing it !!!!!

Sure glad I don't have a job anymore-----it's a long chore if you do a good job.

The top of the windshield and the sheet metal above it is really hard to get to------had to use an 8' step ladder-----------and that's where the bugs get wacked.

It's a diesel powered bug wacker.

Just drove thru my hometown and diesel was a few pennies less than low grade regular gas-------------I'm lovin' it !!!! I don't think it's been cheaper than regular since the mid 80's ???????

Mark
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Nice Cad drawings. What software are you using. I also like the fact that you leave the bathroom available when you are sleeping. I would need it :)
Looks like Google SketchUp to me.
Hello, just got my transit, saw your rear hitch . Did that mess up your distance sensors?
Hello, just got my transit, saw your rear hitch . Did that mess up your distance sensors?
Yes----it did.
Most of the time it's OK---but sometimes it gives me an alert. Of course I have to have it in reverse for that to happen---so it doesn't happen when in drive.
But I sure do like that thing. I always use it getting in the back of the van----I also installed a hand hold to help pull me up into the back.
I guess when I was young I could jump in and out of the thing--but not anymore.

Mark
FWIW, when I have my hitch mounted bike rack on my santa-fe, my sensors give a steady tone, but it does remind me the rack is back there!!!
I wish I could say I have lots to say.
But the van and the camper conversion I did worked out perfect.
Don't think I'll change anything. I just love it.

Got 21---25mpg and used 3 3/4 gallons of DEF fluid in 5,000 miles.
Glad to know how much it uses as I was in the dark till I just filled it.

If you want to read the story of my big trip in it to New Mexico, Texas and Arizona in which I camped, hiked, rode my motorcycle and my bicycle----here is the link.

2015Southwest





Hey Big Dog,

I recognize you from the Husky TR650 forums/threads, small world.

I'm looking to get into a Standup Van late this year/early next year. I'm transitioning out of a Expedition SUV which is less than ideal for camping/bike hauling (currently using a MC trailer) but not much was available when I bought it in '04.

I plan to do a flexible build out for multiple uses, of course bike hauling and camping being two primary ones.

From checking out a bunch last weekend I think I'll go for the mid roof/length. I can stand up in the MR with a couple inches to clear (5' 9"). Part of the roof decision is less $$$ (hopefully to comp for a diesel) and a lower roof height should give better mpg and somewhat easier parking at times. The extended version seems pretty dang long to "live with", but I"m not sure on that account. It seems like most of the issue will come in parking it, especially in my driveway.

The questions I have mainly focus on the engine choice, diesel or the turbo V6. I'm "pretty sure" I want the diesel but I'd sure like your opinions and considerations, also maybe any comparisons to the Sprinter in that regard. I did read through this thread and caught your comments in posts #10 & 11.

Have you had any problems with the engine/trans? I'm just starting to dig around on this forum in that regard.

That 5 cyl 3.2L engine has been in use worldwide in the Ranger Pickup. Of course the USA is not considered part of that market, grrrr. Why, got no idea.

Were there any times you wished you'd bought the gas engine or not at all?

I'm pretty sold on turbo diesel technology but have never owned one, I'm hoping to change that soon.

Have you done any towing with the Transit? I'm keen to know how well that engine tows.

Here's my current setup, sleeping in the SUV. Biggest problem, it's either you or your gear in the truck, but not both at the same time.

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Hey Big Dog,

I recognize you from the Husky TR650 forums/threads, small world.

I'm looking to get into a Standup Van late this year/early next year. I'm transitioning out of a Expedition SUV which is less than ideal for camping/bike hauling (currently using a MC trailer) but not much was available when I bought it in '04.

I plan to do a flexible build out for multiple uses, of course bike hauling and camping being two primary ones.

From checking out a bunch last weekend I think I'll go for the mid roof/length. I can stand up in the MR with a couple inches to clear (5' 9"). Part of the roof decision is less $$$ (hopefully to comp for a diesel) and a lower roof height should give better mpg and somewhat easier parking at times. The extended version seems pretty dang long to "live with", but I"m not sure on that account. It seems like most of the issue will come in parking it, especially in my driveway.

The questions I have mainly focus on the engine choice, diesel or the turbo V6. I'm "pretty sure" I want the diesel but I'd sure like your opinions and considerations, also maybe any comparisons to the Sprinter in that regard. I did read through this thread and caught your comments in posts #10 & 11.

Have you had any problems with the engine/trans? I'm just starting to dig around on this forum in that regard.

That 5 cyl 3.2L engine has been in use worldwide in the Ranger Pickup. Of course the USA is not considered part of that market, grrrr. Why, got no idea.

Were there any times you wished you'd bought the gas engine or not at all?

I'm pretty sold on turbo diesel technology but have never owned one, I'm hoping to change that soon.

Have you done any towing with the Transit? I'm keen to know how well that engine tows.

Here's my current setup, sleeping in the SUV. Biggest problem, it's either you or your gear in the truck, but not both at the same time.

Hey Danke,
Glad to answer your questions and give my opinion.
Sounds like you are getting things figured out for you next purchase.

The Diesel has been perfect------the inline 5 feels about the same as my old 06 sprinter inline 5 which was an excellent motor. Not quite the mileage the sprinter got--------but it was way smaller---the shortest one they ever made-----118" wheelbase.

I just love a diesel motor-------won't win a drag race with the eco-boost but that's not what I'm after.

At 20,000 miles I've had no problems with the motor or transmission---been doing my own oil changes.

As soon as I bought mine the price of diesel took a plunge down------lucky me.

I bought this vehicle to eliminate the trailer---------but did pull a pretty big cargo trailer with it once with a couple big bikes on it----it caught a lot of wind with it's flip up tailgate and dropped my mileage to about 18mpg.

If you ever think you'll pull a trailer-------be sure and get the tow package or you'll be very sorry. Things are different now and you can't just tap into wiring like the old days. I may never use the built in brake controller---but it makes me feel good to know it's there.

I'm not going to argue the Ford Sprinter debate.
Everybody's got their own opinion.
I value them pretty equal-------but would never buy another sprinter.

There's a ford dealer in every po-dunk town in the country.


Mark
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Hey Danke,
Glad to answer your questions and give my opinion.
Sounds like you are getting things figured out for you next purchase.

The Diesel has been perfect------the inline 5 feels about the same as my old 06 sprinter inline 5 which was an excellent motor. Not quite the mileage the sprinter got--------but it was way smaller---the shortest one they ever made-----118" wheelbase.

I just love a diesel motor-------won't win a drag race with the eco-boost but that's not what I'm after.

At 20,000 miles I've had no problems with the motor or transmission---been doing my own oil changes.

As soon as I bought mine the price of diesel took a plunge down------lucky me.

I bought this vehicle to eliminate the trailer---------but did pull a pretty big cargo trailer with it once with a couple big bikes on it----it caught a lot of wind with it's flip up tailgate and dropped my mileage to about 18mpg.

If you ever think you'll pull a trailer-------be sure and get the tow package or you'll be very sorry. Things are different now and you can't just tap into wiring like the old days. I may never use the built in brake controller---but it makes me feel good to know it's there.

I'm not going to argue the Ford Sprinter debate.
Everybody's got their own opinion.
I value them pretty equal-------but would never buy another sprinter.

There's a ford dealer in every po-dunk town in the country.


Mark
Thanks for the feedback.

With 20k miles on it that's solid real world data. My Brother had a earlier Sprinter 5 cyl (1 ton dually HR mid length) and I drove that so I have some basis for engine comparison.

I don't care about rapid acceleration as much as towing performance, mpg, and durability. I typically keep my vehicles at least 10 years/200k miles, which is about where the Expy is now.

For the towing I also tow a double PWC trailer, about 2,300 lbs loaded and have towed a couple utility and car trailers with the Expy but that's the rarity.

Most of my towing needs would be fairly light, my PWC trailer or possibly a utility/flat bed trailer if I take a group of guys riding or for hauling more stuff than fits in the Van (ie moving houses, stuff at work, etc.) It's going to be multi-purpose for sure.

I would absolutely get the towing package and am pretty stoked it includes the brake controller, normally they don't.

For your Van, what rear axle ratio did you go with?

I absolutely want the limited slip for pulling watercraft up slimy launch ramps.

Also, have you changed the fuel filters yet and if so, how much did they run? I was reading one thread here related to that and there was some pretty wild numbers being tossed around. I'm guessing if you boil it down properly it's not that bad.

The DEF fluid consumption doesn't look too bad either. It looks like it was maybe $30 for 5k miles of driving based on a quick net price search.

Are they any other options that you have found critical? I haven't scoured the options list yet, but much of my application will be similar to your's. I'm thinking dual batteries, remote 12v wiring, the 120v inverter, backup camera for hitching up, ???

Have you either added or considered a separate rear roof mount A/C unit?

I'm planning to have a couple extra rows of detachable seats, I have to see about that option, either factory or aftermarket. I've had my Expy filled with 8 people on more than one occasion and being a people hauler is part of the Van's intended role.

I understand your comments regarding the Sprinter, 'nuff said. I know my Brother's feelings also.
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Thanks for the feedback.

With 20k miles on it that's solid real world data. My Brother had a earlier Sprinter 5 cyl (1 ton dually HR mid length) and I drove that so I have some basis for engine comparison.

I don't care about rapid acceleration as much as towing performance, mpg, and durability. I typically keep my vehicles at least 10 years/200k miles, which is about where the Expy is now.

For the towing I also tow a double PWC trailer, about 2,300 lbs loaded and have towed a couple utility and car trailers with the Expy but that's the rarity.

Most of my towing needs would be fairly light, my PWC trailer or possibly a utility/flat bed trailer if I take a group of guys riding or for hauling more stuff than fits in the Van (ie moving houses, stuff at work, etc.) It's going to be multi-purpose for sure.

I would absolutely get the towing package and am pretty stoked it includes the brake controller, normally they don't.

For your Van, what rear axle ratio did you go with?

I absolutely want the limited slip for pulling watercraft up slimy launch ramps.

Also, have you changed the fuel filters yet and if so, how much did they run? I was reading one thread here related to that and there was some pretty wild numbers being tossed around. I'm guessing if you boil it down properly it's not that bad.

The DEF fluid consumption doesn't look too bad either. It looks like it was maybe $30 for 5k miles of driving based on a quick net price search.

Are they any other options that you have found critical? I haven't scoured the options list yet, but much of my application will be similar to your's. I'm thinking dual batteries, remote 12v wiring, the 120v inverter, backup camera for hitching up, ???

Have you either added or considered a separate rear roof mount A/C unit?

I'm planning to have a couple extra rows of detachable seats, I have to see about that option, either factory or aftermarket. I've had my Expy filled with 8 people on more than one occasion and being a people hauler is part of the Van's intended role.

I understand your comments regarding the Sprinter, 'nuff said. I know my Brother's feelings also.
I've got the higher geared axle--------I forget the ratio----3.2 ?????
But I plan to almost never tow.
You might want the lower geared axle.

The Transit diesel already has 2 AGM batteries under the drivers seat. Pretty handy to tie into for powering other stuff or an inverter. If your batteries go dead---there are 2 big terminals under the hood to jump it.

I've bought a fuel filter---but don't remember the price---and haven't put it in yet. I've just heard it's a bit tricky to get the old out.

I think I can go 7,000 miles on 5 gallons of DEF.

I wish I had the back up camera----but didn't need or want any of the other fancy stuff.

Mine has a divider wall---as you probably saw--------it's all un insulated tho-------the heat and air has no probably heating or cooling the whole area.

I didn't order mine--------it was just on the lot---and besides the back-up camera was just what I wanted--------I wasn't going to wait to order one---I couldn't stand that.

Other colors than white sure are pretty---but I wanted the white to reflect the heat of the sun.

Mark
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I would absolutely get the towing package and am pretty stoked it includes the brake controller, normally they don't.
Unless it changed for 2016 the tow package on the Transit does NOT automatically include the brake controller.
Budsky, when I ordered my 2016, I declined the tow package because i was told it had to come with the controller and wiring upgrade/ tow-haul. The price turned me away ($800 or so) as i only wanted the hitch receiver for a bike rack.
Don't know if this was truth or sales bs, but I will put on my own hitch.
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