Weekend Warrior Aero van conversion.
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New User
Joined: Jul 2021
Posts: 2
Likes: 0
From: So Cal area
Weekend Warrior Aero van conversion.
Hey-Ya'll,
New to this group, seeking knowledge on my van conversion. Building this van for weekends in the Sierras, 2 to 3 day trips hiking with a convenient bug out van.
I bought a 1991 Aerostar Ext. Cargo Van, for this purpose.
I made a layout of the floor plan first, and found that every 32nd of an inch matters (as it gets smaller as you come up from the floor. I have installed the Couch that reclines into a bed, and found not enough room unless reclined (head hits the ceiling with 9" storage underneath.
The next step (and the reason for this post) is installing windows in the front side panel and the sliding door. Measure twice cut Once, (or maybe twice) or so.
I figure I'll tape it off, draw the inside dimensions and cut with an angle grinder. Once done (if I don't mess it up) , I'll drill the holes and bolt it in with urethane bond.
Anybody got any tips and suggestion?
New to this group, seeking knowledge on my van conversion. Building this van for weekends in the Sierras, 2 to 3 day trips hiking with a convenient bug out van.
I bought a 1991 Aerostar Ext. Cargo Van, for this purpose.
I made a layout of the floor plan first, and found that every 32nd of an inch matters (as it gets smaller as you come up from the floor. I have installed the Couch that reclines into a bed, and found not enough room unless reclined (head hits the ceiling with 9" storage underneath.
The next step (and the reason for this post) is installing windows in the front side panel and the sliding door. Measure twice cut Once, (or maybe twice) or so.
I figure I'll tape it off, draw the inside dimensions and cut with an angle grinder. Once done (if I don't mess it up) , I'll drill the holes and bolt it in with urethane bond.
Anybody got any tips and suggestion?
Cross-Country
Joined: Mar 2018
Posts: 54
Likes: 24
From: Idaho
I would suggest you plan out the final product, so everything you do now fits with what you want the end result to be.
You want lights, fridge, vent fan, charging points, etc? Figure out your battery location and charging system now. Build wiring a harness to support the electrical equipment, in the locations you want to put it before you cover the walls.
You want insulation and interior walls? Now's the time to sort that out.
Water? Heat? Different floor covering? You get the picture.
Good luck! This is a fun process.
You want lights, fridge, vent fan, charging points, etc? Figure out your battery location and charging system now. Build wiring a harness to support the electrical equipment, in the locations you want to put it before you cover the walls.
You want insulation and interior walls? Now's the time to sort that out.
Water? Heat? Different floor covering? You get the picture.
Good luck! This is a fun process.
Thread Starter
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New User
Joined: Jul 2021
Posts: 2
Likes: 0
From: So Cal area
Thanks Hendricks,
Yes I have a floor plan that has gone 3D, I have put the convertible sofa in, Next is the windows (sliding door and front driver side panel). A aluminum bracket for the TV that folds down from the cramped ceiling. Then I'll install the stainless steel shelves They are on the drivers side jetting out behind the drivers seat where the 13" sink will be. I have two 5 gal. and a foot pump to conserve water. Before I do the plumbing I will finish the elect to the Micro fridge, TV, Convection oven, and vegy steamer.
What I do not have yet, is the two 100 AH batteries, Two solar panels, solar charge controller, and Inverter. price on that is around $1K all together.
I will situate the panels so I can fit A/C over head (that will be next year). And Then take it all apart to Floor and Panel the ceiling, as well as carpet the walls (indoor outdoor High-low).
Thanks for your thoughts,
any other ideas will help.
Yes I have a floor plan that has gone 3D, I have put the convertible sofa in, Next is the windows (sliding door and front driver side panel). A aluminum bracket for the TV that folds down from the cramped ceiling. Then I'll install the stainless steel shelves They are on the drivers side jetting out behind the drivers seat where the 13" sink will be. I have two 5 gal. and a foot pump to conserve water. Before I do the plumbing I will finish the elect to the Micro fridge, TV, Convection oven, and vegy steamer.
What I do not have yet, is the two 100 AH batteries, Two solar panels, solar charge controller, and Inverter. price on that is around $1K all together.
I will situate the panels so I can fit A/C over head (that will be next year). And Then take it all apart to Floor and Panel the ceiling, as well as carpet the walls (indoor outdoor High-low).
Thanks for your thoughts,
any other ideas will help.
Cross-Country
Joined: Mar 2018
Posts: 54
Likes: 24
From: Idaho
Sounds like you have it sorted. What setup are going with for power? I'm using a Redarc BCDC to keep things charged up. I decided not to mount the solar panels on the van. Haven't bought the panel yet, but my plan is to use a suitcase type panel with a longer cable. That way I can park in the shade and set the panel out in the sun.
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