Start to Finish: 2002 Ford E350 Van Life build with NO EXPERIENCE!
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- Опубликовано: 15 окт 2024
- When Covid hit, I decided to devote my time to a new project. I bought a 2002 Ford E-350 SuperDuty Van and completely built it into a Van Life home on wheels. In this video, I will walk you through my steps, thinking and design I decided on and how I built my van!
I had no prior experience so everything I had done had been from watching RUclips videos and reading blogs online - I hope this video is helpful for individuals looking to join the van life!
Hey bud, this looks like a fun build. However, as a former automotive and structures engineer, the point of the metal frame in the roof was to provide structural stability and safety. If you do this kind of build with a similar vehicle in the future, keep that in mind. The steel cage provides lateral and vertical stability in the event you had an accident. With the frame removed the sidewalls are much more likely to collapse because they are mostly securely fastened at the bottom. The same thing for the lack of support you now have if the van was to roll. Think of that steel frame as a roll cage essentially. You are now only relying on some fiberglass and 1x4 boards to keep the vehicle from being crushed. I know that I sound like a serious downer, but I just want to help.
This was what came to mind immediately. The metal frame is very important in the long-term. Some YT channels actually share their experiences when they thought their fiberglass shell addition was enough, which was not the case. With that aside, this is a well designed layout and rest of the build looks great 👍
I had this immediate thought as well.
If there's a roll over, or anything coming down on that vehicle, that roof will cave immediately. 😱
nah i was like wtf put that shit back up
heybud
Same thing, I said I wouldn't drive that. all that glass will break in a rollover 30% Metal holding the top square. and that top will come off, we're talking about 5,000 lb van the conversion are the highest fatality vs even trucks cause of too much window that took away structures integrity.
Metal bar: is structural support for the missing roof. Good luck, Tcash
The frame isn't structural. That wouldn't do a thing if that heavy van flipped. It's because over time in the sun that fiberglass will start sagging in. Happens to truck caps all the time.
Amen! I’m glad someone said it cuz these comments were getting ridiculous! That flimsy frame would do nothing in an accident
I gotta be honest, in the beginning I was thinking you were gonna really screw the pooch on the build. But in the end I was quite impressed with how it all turned out. You did a great job.
Don't know if anyone else has this issue or if it's just me but I thought I'd mention it - there is an issue with the volume on this video. I have my computer at 100% volume as well as the video at 100%, but can still barely hear what you're saying. I would suggest you either speak a little louder or get closer to the microphone.
plenty loud for me at 50%
Love the fact that you're cleaning
To give you some advice about the doors on side. The hinges can be open 90%, if you close the door 25%, then push the latch back a little it will unlock the latch to open wider. After you close the door it will relocate the position, but needs to be done each time you want to open up the doors wider each time.
Saw this on video from Weld Tech design it was on the over view of his Chevy van owner.
Hope that gives you more space to get into the van.
Most times I've heard the word caulk in one video! 16:49 He said "I put my hand in a little caulk!" 😂🤣
To fix your side door paneling, just stop the wood below the lower edge of the window. Remove the narrow section that you ran up to the top of the door. Ending it there, you can just leave the top slate straight across and have a clean edge. Van looks cool!
I have virtually the same van, an 07 with a wheelchair lift. That’ll be coming out.
I’ve yet to start my build although have been gathering supplies and will be starting soon. That interior shell... I’d wondered about that as I want insulation up there and want the wood for cosmetic reasons. I’m going to watch your video again, take a look at that metal frame which I’ll leave in place and work around. I have a separate interior roof air conditioner in the very back... I’d kicked around removing it but I think I’ll work around that as well due to having dogs and wanting them to be as comfortable as possible back there.
I really like your layout, video, thanks for posting. If I can offer a suggestion, slow it down a little so what you’ve done can be viewed with more clarity. Again, I really liked your floor plan there... I’d like to see if I can slow the video down on my end so as to get a better look especially of your entrance way. That... that I’m not sure what to do with yet and need all the inspiration I can find!
Beautiful!
That upper rack is for support on the side Pillar walls and rollover.. As the side walls will just collapse on you or the windows will start to leak. As they will flex....
This video was perfect. I just picked up the same kind of van and was looking for inspiration with the high roof. Also learned there’s more storage area over the driver once you remove the liner
Awesome video and well done project!
Now this is a really nice rig!!
The hanging wardrobe is my favorite thing....so BIG. 😊👌
Man that's Kick-Ass bad man good job
Awesome, awesome, awesome,great job on that fiberglass hole, I've been working and living in my class c rv, nearly rebuilding it from scratch, lol im working on the over cab, the edge curve is giving me all kinds of grief, but sir again awesome job,
Me encanta tu dedicación!!
Amazing job you did buddy great work ,Enjoy your road trips and have fun I have a 2012 ford e 250 I bought mine completed I am not very handy like you lol , Can't wait to see more videos I'm from Nova Scotia Canada be safe.
21:11 That's funny lookin' plywood!
Nice job, getting ready to redo mine, so getting some great ideas!!Thanks,
watching from Denver brooooo.good job.
Excellent work. It’s interesting to see how you built out the fiberglass roof as I am building out a dodge conversion van with a similar roof. Luckily there’s wooden ribs in the roof that are actually pretty decent mounting points. Cheers
Your van looks pretty nice.. you have done a good job... some good ideas for my van build 👍 thanks for sharing
good morning doug nice to meet you. i will be following you, im from out of memphis Tn area.
I have the exact same van.. great job and thank you this helps me get ideas for building mine.. only thing, with zero experience how did you figure out how to do some of what you have done? I mean, the how to RUclips videos, for me, are not broke down enough...I know absolutely nothing about building anything....but I'm going for it anyway.. learn as I go I guess.
Great work man! 👍
Nicely done But I would have built a shower in the back with a Bath room
Good job.
I really like the taping out your design first. I live full time in my 25 foot class A Winnebago warrior motorhome with my little dog Tinkerbell filming. I film all kinds of stuff but my favorite is the creepy and abandoned. I beat kidney cancer and then a little over 2 years ago I hit the road now IM in Ehrenberg Arizona over 30,000 miles a 8 states later! Love the life! Love that you took on this challenge and you did a super good job!
Hey I saw your comment and first of all congrats on beating the cancer second I’m definitely going to check out your channel because I’m in the process of converting a short bus myself, making lotta mistakes but getting there.
super cool i think you did a great job
Thank you for the video... I got some good ideas from your built. Nice job.
Great build! I would urge you to check often under your mattress for mold, moisture can get trapped between the mattress and the plywood, if it becomes an issue you may want to modify the plywood to a slat design.
I have the same exact van.. I was planning 8n the same kind of bed . Is there a way to prevent the mold? (I'm still in the early stages of building)
@@tina7841 just put holes in the board underneath the mattress or use boards across with space in between so it can breathe.
Overall looks good. Those ceiling lights probably run off of 12v after passing through that metal jbox. You should have powered them with one of your 12v outputs on the solar generator. It's much more efficient and less draw on your solar generator. Curious, you only have one seat(driver's) up front, why such a large 2 person bed? Seemed like you could've had more room to play and work with if the bed was for one person. Concerning that the metal cage was removed. Safe travels
Good job
So you took out the structural support for the roof?
Cool build, very roomy.. Everything you need. One thought changing out the emergency roof exit for one of the vans that block the rain and can vent air in or out. Incase you want some air on a rainy day or night. Or want air and don't want bugs being able to come in... And lol is it much more expensive to get a fridge like yours that has both fridge and freezer..? Love my ice cream. Overall you have everything you need and ready to hit the road.
Soo soo glad I found your video!! Been looking for one all day and can’t seem to find any Ford high roof ugh!! Wondering how you disconnected the rear a/c & heater? Hope you made more videos. I’ll check out your channel and subscribe!! Thanks again🥰👍
Thanks for watching! I actually didn't disconnect the rear ac/heat...it vents underneath the bed in the rear
Good luck.....👍👍
I would have kept them roll cage bars to screw cabinets into the metal and it would hold.
I wonder if you can put that extra headroom on a 85 Ford Econoline club wagon XLT but not it's it's 9:54 extended but not big big standed you know
I like the layout. Thanks🇨🇦❤️👍
Curious what your gas mileage is. I’m looking at a similar rig right now.
Nice build.
Some interesting ideas - but quality and safety are missing in many places. That frame has already been spoken of by others so I won't kick that dead dog. I hope you've got some decent design toward finishing those round holes you want for windows. "Outta-sight - outta-mind" attituded is dangerous ... and MAN! you're building very heavy with 2x4s!
Do you notice any flex from removing the steel frame? I’m at the point where I’m trying to decide what to keep and what to cut out.
BRILLIANT!
Questions
1. Wouldn’t it have been easier and more sturdy to put back the metal ceiling support?
2. The floor looks like it’s rusted? No rust abatement?
3. Having an extension cord to lights enclosed under ceiling materials? Fire hazard?
Hey great questions!
1. That's what I thought originally but the metal support wasn't holding up the outer shell in anyway. Therefore, I lost about 4 inches of crucial ceiling space if I left it in place!
2. Slight rust on the floor but nothing too bad. I actually left the original subfloor wood on the floor
3. Unfortunately, I was working with what I had. The lights were much easier to plug in directly to the goal zero battery. Not too concerned about fire hazard since I can access the wiring, if needed
@@thedouglyfe4165 these vans were manadated to have that metal structure. It was not meant to hold up the top, it is meant to make that van not fold like a sardine can \
Yeah that's the thing I'm missing is the headspace
My college roommate doing big things!
Darn, what about cutting that ceiling wood and angling it up so you have more headspace?
Nice solo male build.... you tube needs more content like this form single Men... there are plenty of couples builds out there
@Enkibee’s Journal not sexist.... truth
He didn’t show any of the actual “building” of the van tho. The very first van clip showed an older guy grinding the seat bolts 🤔 SUS
Where are people getting these van tops? I'm only seeing kits and installations for 7-10k.
Hey! We just got this van too and haven't started. (Newbie here) I am curious why you didn't take out the plastic paneling on the sides of the van too?
What plastic paneling are you referring to? I took out any and all plastic paneling, other than on the driver/passenger side
Hey there, do you happen to have a blueprint or any kind of record of your cuts and measurements and all that stuff? Just looking for ideas thanks
Hey! Unfortunately, I do not :/
Love your build, enjoy🚙
Awesome video. I just bought essentially the same van except 2006 model! About to start working on it and have a few quick questions:
1. Any advice/details on how you removed the seats? Mine are bolted down, with a nut on the underside of the vehicle, but they are all pretty much rusted in place and I'm a bit nervous if I do remove those bolts it would leave holes in the floor. I guess I would be covering those with any insulation/flooring I put in, but it looks like you may have just cut/ground the connections down to meet the floor?
2. Similarly, any advice on how to approach removing the plastic shell for the ceiling extension? I had planned on leaving that as is because I wasn't sure how thick it was or how many layers but after seeing this I think it would be nice to customize the ceiling section too.
Cheers and thanks!
1. I just used a grinder. If you see the very beginning, my neighbor actually helped me with this but we just grinded the bolts right out and left holes in the floor - these are now covered with insulation.
2. I had a hole in the ceiling so I was able to see how much additional "customizable" room I was going to get by removing the inside plastic ceiling. I used the same exact grinder to basically cut the ceiling into 6 sections/pieces then took it apart that way. It made a mess but gave me some valuable inches for headspace. Just get ready to build a structure in place for the ceiling (imo, I think it looks way better than if I kept the plastic)
leave the shell alone
I recently removed the shell of mine, I had to remove side panels and everything to get it down, but it was pretty straight forward. It came down in Ken piece, but it’s heavy doing it that way, was probably 100lbs
I wonder if I could order that
Just subscribed... pretty nice setup great job on the build.. keep it up 👍
Can you tell us how you found this vehicle in Mexico???
That closet can double as a shower with a little modifications.
I like your thinking!
Hi! how hard was it to take the metal bar? is it bolted or just screws? im about to buy a e350 and going to do the same. and what's the height inside without the inner roof? THANK YOU ; )
Hey Tiago! It was only screwed in - once the inner ceiling was taken down, I was able to easily access the screws and remove them with a screwdriver. The inside is probably 6 feet without the inner roof (I'm 5 feet 10 inches)
Do you think that metal bar might be important if your van rolled? Just wondering.
@@dawnsmith4275 honestly, no. The metal was very lightweight and definitely would not have helped in the slightest lol
Great build. How did you attached the furring strips to the metal body? Also did you bypass the a/c blower motor unit on left side of van?
The furring strips were drilled into the metal body. The a/c motor was left alone...it's still connected to the cars a/c but blows air through a gap/makeshift vent space between the window and the wall
have you considered the weight of the wood?
Congrats, now you’re getting 8 mpg
I’d kill to have that cage in my fiberglass roof van. What a shame
Good
I don't understand why there's a need to lie about having no prior experience in woodworking etc ? Clearly you have the experience or at least someone else with experience has helped with the build.
Great build ... what battery and solar panel system did you use ???
Battery is goal zero and the solar panels are renogy 100watt panels (2 of them)
The metal bars, aren't they roll bars? It's a safety feature, right?!
Did you drill directly into the metal. With what screws.
yes - I bought self-tapping screws from Lowe's and they worked out well
Omg how much weight is all that wood
I estimated the wood weighed about the same or less than all the metal and seats which I removed from the original van!
@@thedouglyfe4165 that’s great I just noticed a few builders changed out some of the wood they put in due to weight so it was on my mind
What did you do about the side airbags in the back????????
no airbags back there (:
What did you use for the trim on the floor? Looks great
Flooring is called ashville Pine (from Lowes) and the trim is simply quarter rounds which were matching colors!
@@thedouglyfe4165 HOW TALL ARE YOU ?
@@RVingwithG 5 9
What is the metal mount on the dash?
its an old bus. it's currently used to open/close the door from the drivers seat...planning on removing it sometime soon
@@thedouglyfe4165 oh ok, makes total sense. Actually you could lock it for a little more security , lol
I have the same exact van. Could you build mine? I’m in Massachusetts
I'm actually originally from RI! I'm living in Hawaii until further notice, though!
You will regret taking out the frame inside the fiberglass top.
Really great job on your conversion. I’m in the process of building out a short bus and the best thing that you did was to completely gut yours out and reinforce your fiberglass ceiling. And I also have no experience with mechanical or carpentry or electrical and let’s just say that I will be making a lot of trim to hide a lot of my mistakes LOL. Putting up the frame and the taping on the floor was an excellent idea I kind of screwed up on that and that’s what caused me later issues.
I think I've made the same mistake... No tape as guide... currently building a shuttle bus and 0 experience. Yay for learning, trial and error 😅
@@pyrokittykat744 Have you posted or will you be posting any videos of your conversion? If so let me know I definitely still watch other conversions regularly.
@@pyrokittykat744 even with the mistakes I’m pretty sure I’ll be happy with my bus. Although I would definitely have done the conversion differently I’m not going to re-gut it to start all over again.
@@mobilehomelife4028 I don't have the skills or equipment to post vids to RUclips... but I'd be happy to share pix and stuff on Discord.. feel free to add me PyroKittyKat#8772
Cool van but there’s no actual “building” shown in the video. It’s all before and after. The explanations are helpful but it would’ve been nice to see the actual build process like most van build videos. Nice van tho
Ceilings
That doesn't look that hard to actually put on I know couple welders and it wouldn't be some metal and some welding and boom I can have that topper to
👍
Interesting video and build but I had to quit 4:45 into the presentation because you made me dizzy with all that camera movement. You need to work on your videography skills. Good luck.
I need to buy and get a van ready with like 2 grand I know not that possible
You'd be surprised 😊 I picked up a ford E450 shuttle bus for under $1k. If you can travel to personal view the vehicle first that is most definitely recommended... but visit GovDeals . Com
I hope this helps, they have vans, trucks, buses and more💖 Best of luck 🌺
No..no.no...put that structural bars frame back...travel safely and not so fast...🙏
like 🌺
u forgot shower n toilet
Round windows in the back are blocking your driver's view completely obstructing your view out while driving completely. Need to cut those out immediately or it will not pass inspection in some states 🤔
And yet so many of this style work vans have no windows at all in the back doors. It's a head-scratcher.
@@wrylife57 😂 best comment award 🥇
You talk too much. Don't tell us what you're gonna do. Just do stuff and then tell us what you did. Much faster.
Didn't show any building