Over the past few years we’ve rented Class-C campers for trips to Yellowstone and Death Valley National Parks. The experiences have been some of our favorite family memories. They’ve also started family conversations about owning our own RV or camper van. A few weeks ago, those conversations become more of a reality when we purchased a 2014 Econoline Cargo Van. We’re in the process of making it into a camper van or more realistically a fancy tent on wheels. Here’s what we’ve accomplished so far. Oh, and when I say ‘we’ I mainly mean my husband and father-in-law:)
2014 Econoline Cargo Van
To accomplish this project our target overall/all-in budget was about $15,000. We figure we’ll use the van about two to three times per year. Our budget was set with the idea that we still wanted to have money for other types of travel, kids sports camps, etc. We think we found just the right vehicle in this 2104 Ford Econoline Cargo Van. It has about 200,000 miles but is in really great shape. Dirty but in good shape. As an added bonus, this particular van already had running boards to make for easier access in and out of the van. In total, we paid less than $9000 for the van.
We will be sleeping and transporting four people. This van already had a bench seat with the needed capacity to have our boys ride comfortably with seatbelts. The plan is to also use the bench seat as a sleeping space with the help of a inflatable mattress. More on how we will accomplish this later on in this post.
Camper Van Build: Step One-Rip It Apart
Our boys are so excited about the van and have been big helpers in the cleaning and tearing out process. They’ve been ripping out metal shelving units and even got to use a box cutter to help cut out the nasty carpet that covered the passenger area. The most difficult part of the tear down process was removing the bench seat. It’s bolted to the frame of the van and was rusted in place. No amount of muscle or liquid wrench would make it budge. We ended up taking the van to an auto repair shop where they hoisted it on a lift and were able to cut the bolts off.
Once the van was emptied we were able to see what we were working with. The next step was to grind out the rust spots, patch any holes with resin and then paint. Looking like new!
Camper Van Build: Step 2-Sound Proofing and Sub-Floor
With the van gutted, patched and painted, we were ready to start working on sound proofing and installing the sub-floor. Reminder, this is a cargo van so nothing but metal separates the inside from the outside. To make for a quieter and more comfortable experience we lined the floors and eventually the walls and the entire van with Rattle Trap. Rattle Trap is a sound deadening material that captures sound vibrations and helps eliminate road and engine noise. It has an adhesive side making it easy to stick to any and all of the van’s surfaces.
In the picture above you can see strips of Rattle Trap stuck between the ribs on the van’s floor and covering the wheel wells. Next, 2×2 strips of wood were shaved down about 1/2 inch to lay between the ribs of the floor. Next 1/2 inch foam insulation was cut and wedged between the 2×2 strips.
To complete the subfloor, 1/2 inch, sanded birch plywood was glued and then screwed down. The intent is to finish the floor with vinyl sheet flooring. The birch plywood offers a smooth finish. The screws were also counter sunk to further ensure the finished floor would be free of ridges or divots.
Camper Van Build Step 3-Framing and Insulation
With the subfloor complete, we tuned our attention to insulation and building the bed frame. For insulation we chose sheep’s wool by Havelock. Since the wool is an organic material it is naturally moisture resistant. This is important since the van will subjected to dramatic temperature swings and condensation. Before we would plop the insulation in place, we first needed to frame all the walls and the ceiling. The framing will provide ribbing to nail the future planked walls to. The framework is created with 1x4s.
To create a platform for the bed, we used 2x3s and three-quarter inch sanded plywood. The dimensions of the bed will be 53 inches wide and about 70 inches long. It’s just short of the size of a standard full sized bed. The height of the bed platform and the spaces below the platform were designed around the dimensions of our Yeti cooler and Blackstone grill. The cooler and grill are critical, since they are our refrigeration and means of cooking.
The space below the bed will be known as the garage and will serve as our primary source of storage. Before screwing the bed’s platform in place, we glued down sheet vinyl flooring. The vinyl is economical and easy to install plus it will be easy to maintain. With the flooring finished and the walls and ceiling prepped, we turned our attention to the electrical and ventilation systems.
Camper Van Build Step 4-Electrical and Ventilation
With just over 70 square feet of space and four people sleeping in the van, air circulation is important. We purchased the Maxx Air 7000. The fan has variable speeds, is programmable, runs off a remote control and has a rain shield so it can be used in inclement weather. Installing a fan allows for better circulation and reduces moisture in the van as well as provide the ability to cool the van on warmer days.
The fan runs off a battery powered electrical system using roof mounted solar panels. To create the electrical system, we started by mounting two-100 watt solar panels to the roof of the van. The panels are connected to a Renogy 12 volt, 100 amp hour deep cycle house battery. To regulate the voltage to the battery, we also used a Renogy charge controller and a 12 volt distribution block. The system uses 12 gauge wire to distribute current to the van’s 6-LED puck lights as well as the fan and 2 USB power outlets.
The battery sits just behind the wheel well and we built a shelf over the tire to house the rest of the electrical components.
Walls, Ceiling, Storage and Final Touches
The walls and ceiling are covered in tongue and groove pine planks. We stained them a light whitewashed color. The planks have a beaded and a smooth side. We used the beaded side on the ceiling and the smooth finish for the walls.
For the bed, we purchased a 4 inch foam mattress topper. We chose this option because our bed frame is just short of a standard full sized mattress. The foam topper allows us to squish the pad into place and we could have trimmed it if needed. Plus the topper is inexpensive, around $150 dollars. To complete the bed area, I added a neutral colored comforter and a few pillows.
The van is a tight space. Every inch of space needs to serve a function and provide storage. My husband and father-in-law built the over the bed cabinets. We use these to store dry goods and a few kitchen items. The under the bed or garage space storage houses a Yeti Cooler and Blackstone grill as well as bins for clothes and jugs for water. We use bins under the bench seat for storing toiletry items, electronics and miscellaneous “stuff.”
My favorite finishing feature on the van is the scratch off national park map. It’s a great reminder of the family adventures we’ve been on and is fun to track and dream about future travels.
In about 10 weeks were were able to take the van from cargo to comfortable. Our first family adventure will be in Joshua Tree National Park. Click here to read all about our adventure.
For more on the early van build process, check out this video.
Happy Adventuring, Rochelle