2005 E Series Van Conversion
The towel rack I mounted to the panel that originally held a flat screen tv, which was a total waste of money, above and behind the front seats.
That's all about to change though. I have all the parts that I need to install the house battery and inverter along with lights and other wireing. I also ordered insulation which is going to be the step after the wiring. I'll start on the wiring any day now...
Always have the inverter accessible, so you can get to the on/off switch, obviously don't want it on at all times, and most importantly, nothing touches it, have space around it, in case of spark and to allow cooling, air must circulate.
I think in tight places, those enclosed, I'm going to spray in the expanding foam insulation, inside the walls only, maybe up inside the door toward the window openings. The factory stuff in my 15 passenger works quite well, my sound system stays inside, doesn't leak out, but I'm going beyond it since I want to replace the plastic panels with more custom designed, made from thin wood.
I'm not building a rolling speaker box, I hate those, I want to retain daily driver status, yet be able to sleep in it, and everything has to be neat as I plan to show it. I have cut some trim panels from cedar, 6'x6" and drilled each with 20 holes for LED pods containing 2 each, and attached them to the ceiling, I have them on a relay that's triggered by the opening of the doors. I bought many loose LED's that require soldering and adding resisters, I'm going to hide them in panels and trim, only to show when on, may link to the doors or a switch, not sure which. I love how LED's put out a lot of light, draw little power, no heat and are so easy to hide, I'm using blue currently, but will have some other colors on a selector switch.
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>That's some good information. What is a rolling speaker box? I am staying away from the spray in foam; I've heard good things and bad things about using that stuff. The good thing is it makes your van very quiet. The stuff may off-gas and it is difficult to remove if you need to. I am planning to put the inverter in the back under the bed that will eventually be built. I agree to keep the inverter accessible. The one I bought has a optional remote shut off, but it seems just as easy to keep it accessible. I'm going to run 1/0 wire on the battery so that in a pinch I could also start the engine with it. I'm also using a solenoid to isolate it from the starting battery.<o
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>I'm thinking of a sound system and now is the time to think about it. I'm going to take some pictures so I can post them as the project progresses. <o
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The place I'm talking about foam is up the tight area's where you can't insulate, the pillar areas around the windows, I have a window van you see.
A rolling speaker box is the vans walled in the rear with speakers, turning the rear of the van into a box, you can't do anything with it.
After one winter, experimenting with different heaters, I learned that moisture control in the interior in very cold weather (-20F and lower) is a big issue.
Working on that issue now.
Ford Trucks for Ford Truck Enthusiasts
Home depot sells this stuff: Thermwell 12 In. x 15 Ft. x 1/8 In. Self-adhesive Foil/foam Duct Insulation - FV516 at The Home Depot
I plan on getting it soon and doing the all of the interior panels and hopefully put up some type of cloth on top of it. Maybe with spray adheasive.
Also be sure to make a window drape out of thick material, all the glass causes easy heat/cold loss.
This winter I used: Mr. Heater - America's Most Popular Portable Heaters
It works very well, last about 7 hours on one tank. It does have a smell, but leaving both front windows open about 1.5 inches with rain guards does ok for venting the smell.
I found that keeping it mid van worked best for even heat. Once I get the insulation mounted I'd bet that heater will be great for sub 30 weather.
The problem is not so much foam eats steel, but the fact that improper use of the foam means moisture is trapped.
I elected to use none of it (or very little, e.g. like filling in joints) because of that.
Most of my boxed sections were left "open" so it does not trap moisture.
The heat loss reduction from insulating (eg the upper door window frames insides) is negligible.
You are better off to put a layer of carpet on the inside.
I did use insulation in sealed plastic bags inside the side / back doors, and insulation on the front doors between the factory vapor barrier and the plastic trim.
Right now, the biggest heat loss is front windshield / glass area.
Followed by back 2 windows.
Got any ideas?
I had a simple sunshade on the other van, (metal fabric) and it may or may not have something to do with the window developing a large crack after sitting in the sun (evening sun) all summer.
So there has to be a barrier that blocks the heat, but do not allow temps to go too crazy / thermal stress.
I am looking at RV like solutions, but the issue is always space--- want it to be easy to fold up and put away.. maybe a self inflating like foam mat, with foil on both sides to reflect heat?
Ideas welcome.





