After watching van builds for 10 years. This is still one of the ones that stand out for quality and design. This is now my favorite kind of video. What works and what you would do differently. I'm 95% complete with my van build. I hope I am as pleased 5 years from now as you are. 👍
Great follow up Ken. Your videos inspired me to do my own DIY and your ideas are still influencing me. I changed my mind on the fresh water tank and plan to use 4- 5 gal Gerry cans (with your quick disconnect/check valve system) instead of one big tank. Two vents installed, two windows installed, flooring installed and this weekend two flarespaces will be installed and I will finally be ready to start with the inside cardboard mock up to be followed by 8020. I've watched 100's of van DIY videos and still come back to the Ken method. Thank you for your guidance, instructions and inspiration.
Super nice complement, thank you! When using a number of jerry cans I would recommend doing your best to keep the supply lines to each tank close to the same length. If using four tanks, perhaps two sets of T's might be one solution. It's amazing how evenly the tanks empty in unison. Let me know if you need anything and thanks again!
You are such a good teacher, Ken! I've seen your initial van build and it was so advanced for its time. I was impressed with how you patiently and with humility, explained it all to us neophytes. It was therapy for you, and also for us watching it. It is a work of art even today, way ahead of its time. Every detail shines. You did a fine job helping yourself and your daughter get over the trauma. I lost my adult daughter to cancer in Jan 2020 to cancer. I try to lose myself in van builds, exploring, creating. and distracting my brain from that horror. It is enormously therapeutic to listen to you, the quiet voice of reason and technical perfection. You have touched so many. In every video I learn a lot. Marmoleum - a modern take on linoleum. Bio friendly, durable, easy to install and maintain. Its making a comeback. Van building relies heavily on knowing all the raw materials to use. Research is exhausting. Thanks for this shortcut. Smart Batteries - Lithionics is the best Lithium brand to get at present. It has its own BMS. Very pricey, but very reliable. Batteries and tires make or break your van. Smart idea about multiple fuse distribution centers. I have to redo my old Class C and its a scary thought. Now I know that I can install several of these fuse boxes and not have to run wire all over! If you want to know best materials out there, watch the Humble Road Videos. George started commercial van builds and has weekly videos and tips that are so rich in content. He also swears by Thinsulate and Mass Loaded Vinyl for sound deadening. Typically on the ceiling, for max insulation, he uses MLV first, then Thinsulate with white side facing interior, then Reflectix bubble wrap over the Thinsulate. Apparently, when the fluffy side meets the Reflectix, it acts as an air barrier and thermal break. Then he installs a floating ceiling in sectional panels that are removable. Wiring is accessible due to the removable ceiling. Clever, isn't it? I remember when you ordered that double sliding chair that opens into a bed. The best one that I've seen so far is the very recent Kabe Affinity van. This van was designed by a Polish guy, and launched by Kabe, a Swedish company. It was being shown in Caravan Salon in Dusseldorf. There is a double passenger seat much like yours. It unfolds into two single beds! I was so blown away. I watched it unfold 10 times to memorize the mechanism. Two separate single bunk beds from a passenger double seat. Your daughter will love it! It also has an expanding garage with a rear double bed on linear actuators. Fun stuff. Thanks for sharing! Glad to see you back in action. Greetings from California!
I finally found the double bed seat you mentioned, that is totally wild, thanks for sharing that. I can’t thank you enough for the kind words, means a lot. I am so sorry to hear about your loss. Life sure provides twists and turns and all we can do is try and adapt and make the most. I wish you the best of luck and hope to see you out there sometime.
In 2018 my wife and I purchased a brand new Sprinter to convert. Your videos were a god sent. Although we went the route of Adventure Wagon kit and Trail Kitchen chuck box we followed your practical approach when approaching fan, window additions, swivel seats, etc. We finally sold the van in 2021, which we missed almost immediately. Fast forward to February 2023 and we're back but in this case we purchased a 2019 Metris with a poptop that fits in the garage even with the 2" lift kit. Currently working on the basics sound deadening, insulation, house battery system and most important a gas fired espar. Yes a much different animal but in many ways the same except smaller. Thanks again for all your insights and help. Wishing you and family all the best!
Hey Ken, Am about 2/3 through a short wheel base Sprinter van build. Like you and others, I have spent countless hours online, researching thousands of sites, what to do and how to do it. Hands down, your site is superlative! The best I have seen. You inspired me to use 80/20 although I am a woodworker. Marrying the two skill sets has paid off hugely. Keep up the excellent work buddy! Alan
Thank you Alan, that's a huge compliment! I hope you enjoy working with the 80/20 as much as I did. I like the aesthetic, but also the weight savings, strength and adaptability for future add-ons.
Ken you are certainly a craftsman and it is proof after five years. Also an excellent videographer willing to share your knowledge. I’m about a 1/4 into my build. Previously I had a teardrop trailer. Well made but the builder applied a lot of marine varnish to its interior plywood wall cladding. After four years of owning it, the teardrop continued to off-gas VOCs. So I am attempting to construct my van with green materials. I used for Marmoleum for my flooring and it is amazing. Really like it and would recommend it to anyone. It is tough too. Anyway, I appreciate your follow up video. Unlike 90% of the factory RVs which are engineered to fail, your’s is a testament of what should be an industry standard. Good on you I vote yay.
Thankfully there is a wider range of environmentally friendly products available now than when I started on my van. The only off gassing I still occasionally get is from the rubberized coin flooring when it’s exposed to direct sunlight. Thanks for the feedback on the marmoleum. I truly appreciate the complement and wish you the best of luck on your build!
Awesome build Ken! I used 80/20 in my Astro because of watching your early videos. If I do a rebuild I would like to install the Rock & Roll Bed. Happy Trails
My upholstery work in my van and headliner shelf were done spending countless hours studying your channel, and I often get complements on how professional it looks. Besides the massive savings from doing it myself, the satisfaction makes it so much sweeter. I can’t wait to execute more of your innovations with my own twists in my 2021 sprinter
Thanks for posting this. I have learned so much from your original videos. I, and so many other appreciate your videos. I am doing my water system just like yours now. Take care.
I used Marmoleum and it was getting scratched up almost immediately. I wanted to love it, but just couldn't. So I got a large sheet of marine coin vinyl flooring and made a large removable mat for the entire floor and I love that. Super durable and also has more traction for my dogs.
Thanks for sharing, that is disappointing to hear. I suppose every product choice has it's downsides. I have coin vinyl in the rear of my van and while it is durable, it's downside is difficulty of sweeping/cleaning. I'm still happy with it though. -Ken
Hi Ken, I watched you from the start and George from Humble Road. I'm was sold on using 80/20 from you two. I have to admit that I'm in the same boat when it comes to working with wood. Anyway, awesome build and I'm glad you and your daughter are enjoying the rewards. 🙂
I credit the aluminum framing for giving me a much nicer and safer (and lighter) build than I would have had using wood. Thanks for following along and good luck!
Awesome how well your build has stood up. I watched your build videos & you are far to modest, your patience, your research/ planning, & execution is some of the best I've seen even up against the pro builders. Your videography & explanations were super well done & anyone contemplating a build would be wise to subscribe & watch each of your build vids Big Thx !!
I watched when the build was going on. You should be proud Ken, it’s a beautiful build and has held up great. I’ve seen several vans that were built with wood framing needing repairs after 2 years or so. Thanks for the update.
Well done on doing a proper build. I constantly find myself commenting on builds that give no consideration to vehicle dynamics and collisions/accidents. Most builders don't have a clue and are creating death traps. There are some good videos on here showing factory built campers in collision testing which may scare you. Not a magnetic knife holder in sight which makes a change. Even those damn magnetic spice holder tins would become projectiles in an accident. All budding van builders need to watch this video and appreciate the thought that has gone into it👍
My wife was an biomechanical engineer that worked evaluating forces in crashes--and you're right, those RV crash videos are super scary. The magnetic knife rack thing I will never understand--totally agree with you!
Plumbing system worked like a charm. Going on 3 years now. I use one 7 gal container for fresh and one for grey under the counter. These check valves are money!
Thanks Ken, for the 5 yr update. Your site was the one that inspired me towards DIYing our 2016 van. We are still DIYing and are enjoying it along the way as well. I don't know that I have a ton to add but just my contribution of appreciation for your sharing the quality work that your have done. I just wish I could get 100% comfortable drilling holes in my van, lol, lol.
Drilling holes in the van was never a favorite of mine, but it does get easier. Thank you for the kind words and I wish you many years of enjoyment from your van!
Hi Ken Thx for doing a self review of wear and tear. I think the overall product was better than many pro builders. I built my sprinter 170 van in 2018 I wonder if you kept the DC to AC inverter up front - to send ( ac power thinner wire ) to the charger at the rear then AC to DC again? I liked this idea - wondered if it worked?
That's a huge complement, thank you. I do still have the forward inverter. I have only used it once for an extended period and it did great. Solar has met 99.9% of my needs, so I simply haven't used it much. The infrequent use is why I went this route vs a more expensive battery-to-battery (B2B) charger and all the associated heavy gauge cabling. If you forsee the need to regularly charge via alternator, a B2B is probably a better path.
Watched your original build years ago and particularly liked the 80/20 aspects. So much that I am putting them to use. I am finally starting my build on a 2020 170 crew 4x4. Couldn’t be more excited. Thank you.
Hello from the Seattle area. I found your channel and website this morning and it has kept me from my weekend chores! :) Really enjoying it as I think about embarking on a conversion myself. I am also a cruising sailor as well and enjoyed the comparison on your website to a cruising boat. What do you do for toilet needs?
I saw that you used 1.5-inch 80/20; would you do these cabinets in 1-inch 80/20? What was the reason for using the 1.5-inch 80/20? I am building my van and like the 80/20 features, but I would love to use the 1-inch 80/20 to save space. Thank you for great videos!
I built one cabinet out of 1 inch and since have moved exclusively to using 1.5." While the 1" is definitely better than wood, the fasteners (usually 1/4-20) used with the 1" are far smaller with considerably less strength than the 5/16" fasteners used on the 1.5." The larger material has more profile styles available, more fastener options, and more accessories such as pivots, hinges, etc. You can recess 1/4" plywood into the 1.5" too. Just a few of the reasons. The only place my cabinet "loses" space is the dividers between the drawers. You could use another material there to save space if you wished.
Just loved watching your build, attention to detail plus the in depth videos and knowledge sharing during the whole process. So it was just fantastic to see the update, thank you.
The only one I seen someone use ENT Conduit... As I use that stuff in my RV build...Blue for 120 volt, Orange for 12 volt wiring...As these are vehicles. Not a damn house.. That does not see Vibrations, Flexing, Chemicals around the wiring etc...So you should wire them with that in mind....Not to mention easy to service or add wiring later......
Hi Ken Thx for doing a self review of wear and tear. I think the overall product was better than many pro builders. Did you keep the DC to AC inverter up front - to send ( ac power thinner wire ) to the charger at the rear AC to DC again?
Yes, the forward AC inverter is still there if I need it. I don't need it very often but it's nice to know I have a backup. Thank you for the kind words!
Thanks for the update. I've been viewing your channel for my current build on a 170 Sprinter. Your videos and details have been so helpful and encouraging. Happy Trails and God Bless!
I see you have auto plates, not commercial - did you have any issues at DMV to change them? Do you know how much you save in DMV fees with those? Great vid, love your quality and want to build the same headliner shelf next.
you can be justifiably proud of your setup. so many great ideas and thought processes. thanks for sharing. really enjoy watching your videos. While the aluminium sections are great for keeping down weight they can be prohibitively expensive here in Australia. There are other 'non wood' options, we have been testing for some time.
I’d love to know what you find. I’m super interested in alternative products that are lighter, stronger and more sustainable. Thank you so much for the nice complements. 😀
Another great video. Not much wrong here. 2016 seems like so long ago and you were on the leading edge with this build. High quality build anyone can duplicate if they have your dedication. I would have watched regardless, but maybe the title will net some additional viewers and potential business. Ken, if you ever need some content, you could always share some additional trip videos. Enjoyed your past vids. They don’t need to be personal. Just where you went, what you saw and how capable your 2wd sprinter has been to get you there. I’ll be interested to see how the van changes to accommodate your kiddo as she grows. Pop top? All the best!
Thank you! I don't plan to stop making videos...I really enjoy the process. I will continue to share our travels as well as upgrades and happenings with the van. While not detailed on this video, the cabinet adjacent to my daughter's bed slides open and it's padded at the same height as her bed, so her feet can extend all the way to the wall of the van. As long as she doesn't get over 5'10" we are good! :) Thanks for the comment and for following along! -Ken
Great work…I am basically duplicating your build…including factory headliner…where did you source the connectors with check valves for your sink tanks ? Thanks ! Great quality work right here 😊
I value your five-year update on things. Have watched most of your YT vids multiple times, so you indeed have influenced my thinking! Yes, maintenance is seldom discussed. Last year I bought six of the five gallon jugs to use, but then decided otherwise because I was not grokking how to daisy-chain them. I've been leaning toward the Humble Road approach of installing an eight-inch access portal in the top of the water tank for viewing and clean-out. Those jugs have gotten mighty expensive so the tank would have been a less costly approach. Now that I saw the check-valve I understand how to use it. My only concern, then, is that for water we would drink, I would run that through filtering and UV, still doable with your system. We could do the two up front like yours and keep any additional (as needed) in the garage. I'm looking at using smaller cross-section extruded aluminum. Mocking that up soon.
Your plan sounds good, the advantage of course of having a tank under the van is less space taken up inside, but it can freeze, harder to fill in remote locations and there’s the cleanliness issue. What I don’t get about the access port up top is you would need to drop the tank every time you want to clean it. I open up my containers and dry them completely when not in use. And yes you could use filtration with my setup. Good luck with your build and thanks for watching!
With the lizard skin spray, is it pointless to spray it on the beams that stick out from the van right? Seems like you can save by just spraying it on straight sheet metal? Also do you think it does much to spray it on the floor? I’ll be insulating the van with thinsulate and poli board on the floor
I'm not sure if it's pointless, but those support ribs are either spot welded or structural adhesive glued to the roof panel, so it's going to conduct some heat through. I did spray mine, but I taped off the ribs that face the floor so as to not create a problem when I reinstalled the factory headliner that uses plastic pushpins. I think spraying the floor may have very minor benefit to retaining heat, but I would say not nearly so much as a roof or sides of the van that subject to direct sunlight. -Ken
Thank you for the video...and all the info you share. Around minute 13:30 it shows gray recess inserts for the black switches on the pillar. Where did you find them? Thx
I am an amateur woodworker. For a person like myself who has some (limited) woodworking skills would you still suggest the use of aluminum extrusion for cabinets etc.?
For me the aluminum allowed me to build a relatively lightweight, adaptable, strong (safe) and beautiful cabinet without the woodworking skills required to pull that off with an all wood cabinet. I would absolutely do it again even though my wood abilities have improved a bit.
I am curious, did you used Lock Tite on the 80/20 anchor fasteners? I saw that you used it on the all of the other connections but I didn't see it on the anchor fasteners. And if you didn't, did any of those come loose over the 5 years? Thanks for your detailed videos and site!
Using loc tite is recommended but I did not. I’ve had a couple that loosened over the years, which the loc tite would solve, but it hasn’t been enough of a problem for me to back all of the fasteners out to do so.
What a circus with the battery!?! Talk about bleeding edge technology. Lithium was new to me and although I've not anything happen like you I've still had some "do I have a matching pair of $2,500 boat anchors" moments. Once I learned that's BMS' didn't like the inrush of the inverter and how to pre-charge the inverter it's been smooth sailing. Cheers!
I mentioned the need to pre-charge the inverter because I often learn just as much in the comment section as I do from the video. Hopefully I will save someone else a week of stress while wading through shaky support from both the battery and inverter sellers trying to find the person who actually knows what they are doing. None of the documentation that came with Victron inverter or the LifePo4 batteries mentions the need to pre-charge.
Wow… first time I watched your channel. Great review of components and loved the electrical tips and window reviews. Also your water advice can be used for campers as well if they need to fix water leaks to the fresh water tanks.
I would recommend instal Webasto under the van I made specet stainless steel box for it and what you win les noise. And space. All else is super made :) I planing to sell my van and get like yours sprinter :)
Thanks, Ken! Your 5 year review already has me thinking in new directions. What are the top 3 noise makers inside your van when driving? Were they noisy from the start or did they get louder over time? And, last, does that CRL vent window (the one that doesn't close flush) whistle?
Hi, I have a couple of rattles but not sure where they are coming from. I believe one is in the sliding door. The other I think is the refrigerator but it’s hard to tell. The van is fairly quiet on most roads but the rattles do come out offroad. The crl window does not whistle, thankfully. Thanks for the kind words!
Hi, do you have a video about the rear seat and rails that you’ve used (perhaps with install), as it’s such a great idea. PS The quality and simplicity of this video with clear communication absolutely enthuses me to go through your back catalogue - especially as you’re so seasoned. Great work!
Hi, I do have a video on the seat install. It was technically challenging since I needed support brackets to tie into the vehicle frame. I had to secure help from a friend with this one. ruclips.net/video/uqk-nkqjemQ/видео.html Thank you for the kind words! -Ken
Hi, the link that you have goes to a webpage when you click on those to try to get more information it’s not working could you check on that and let us know I wanted to definitely get some more information on this cabinet builds and which part number you were using for the extruded aluminum thanks very much the videos are great
maaaan i love this video. so in depth all infos included. I just wanted to know what your material is called. the gray one with little "dots" in the back of your car to make the box for your electrical system over the aluminium
how did you wire the additional fuse panels? I didnt see that mentioned in your electrical blog posts. are you just running a thicker gauge wire spliced in right before the first main due panel? or do you run it out of the first fuse panel?
I talked to Blue Sea first to see if this was advisable. The fuse blocks I use are rated for 100 amps and can be daisy-chained as long as you never pass more than that through. I calculated my max DC load at 60 amps, so I have a 60 amp DC breaker and wire to handle 60 amps passing through three linked blocks. The advantage of doing it this way is I don't have a spaghetti of wires running to a single fuse block. One is located at the battery, one behind the galley for those loads and one in the overhead cabinet to run displays, charge ports, etc, in a pass-through fashion. I hope that helps.
Now would you still use the small sliding windows in the back, or would you prefer the small RV style tilting windows that allow to be open during rain ?
Now that there are glass bunk windows that tilt open, I would probably really like those, as long as they have integrated screens. I am not a fan of the tilt-out poly carbonate windows due to the non-tinted aesthetic, but that is personal preference.
I'm really interested in how you covered your garage area. Looks like a plastic coin covering on wood. How did you get it to attach to the extruded aluminum?
Ditto the customer service and sporty quality on the CRL window. The glass on the flap wasn't glues flush to the hinged and had a gap in it..yet it still had a "passed" QC sticker on it!!
I was looking on your site for info on how you built your countertop but didn't see it. Maybe I was looking in the wrong place? Anyway you mentioned it was built from 1/2" plywood. A couple of questions: #1: How did you build up the edge of the countertop? It looks to be at least 3/4" Did you add a strip of solid wood around the edges? Or a strip of plywood? #2: Can you explain a bit about how you did the laminate? Or do you have a video about this? I looked for it but didn't find it. Thanks.
I used 1/2” Baltic birch and a friend helped me glue a thin veneer of bamboo over the edge to make it look like solid bamboo, trimmed it flush with the edge of the plywood with a trim router, and then put contact adhesive on the top surface of the plywood and under the Wilsonart laminate. Lay a bunch of wood dowels on the surface and working from the center out, press the laminate down while pulling the dowels. I don’t have a video on this but there should be many on RUclips. I hope this helps, it all looks just as good as the day we did it.
I used 1/2” Baltic birch and a friend helped me glue a thin veneer of bamboo over the edge to make it look like solid bamboo, trimmed it flush with the edge of the plywood with a trim router, and then put contact adhesive on the top surface of the plywood and under the Wilsonart laminate. Lay a bunch of wood dowels on the surface and working from the center out, press the laminate down while pulling the dowels. I don’t have a video on this but there should be many on RUclips. I hope this helps, it has held up well.
Really appreciate you showing things after 5 years, Nice job. Some intelligent choices, like the water and others. Is it ever a problem to lift the bikes so high and secure them? So I guess you live in the Sac area?
Yes, I carry a small ikea stool in the van that I need to get the bikes on and off. From my perspective that helps make bikes more difficult to steal since the locking arm is the highest part. If a thief wants it they’ll get it, but bring up high slows them down. I am in the sac area-glad you enjoyed the video!
I want to buy one of ur refrigerator- sink- draw cabinet system only in the reverse setup. That is to say it would be in front of the barn door with the cooking system near the door then the draws then refrigerator. This shouldn't be a problem reverseing this to my configuration would u think? How much would this cost me? Awaiting ur response! Thanks for ur time and efforts.
The bamboo is from the company Plyboo and I have purchased it from two separate hardwood stores in my area. Both were able to order it for me without any issues. If you live in central California I can share where I bought mine, but I would check around locally first. Thank you for the very kind words!
Your van is looks amazing and I love your videos. I've started working a little with 8020 and was wondering why use the 15 series over the 10 series. I've noticed that the 10 series is cheaper and seems strong enough for most cabinets; however, I'm new to 8020 and it could be that there are some huge advantages to 15 series. Thanks again for all the wonderful videos.
Hi, I discuss the 10 series vs 15 here: ourkaravan.com/8020-extruded-aluminum-van-cabinets/ In short it comes down the fastener strength. If you use something other than the small 1/4-20 carriage bolts that fit in the 10 series, it’s probably fine. Anchor fasteners are very strong but very difficult to do at home, hence why I stick with 15 series. I sure appreciate the kind words, thank you!
@@ourkaravan so it just drains from sink to the ground outside? I swear I saw you put one in, must be confusing it with the video where you made your shower water tank.
If I let it, it would drain to the ground. Laughably I’ve been carrying around a 2.5 gal tidy cat container I put under the van if in an environmentally sensitive area or in an established campground. I always use environmentally friendly soap regardless. We have so little wastewater I’ve realized I really only need a 5-6 gal gray water tank, and will use the space under the van for something else.
Thanks for this video. It confirms a few choices for me. How is your fridge working for you? Do you have extra insulation around it for warm weather camping?
Fridge is great. Some do add insulation around them, but the fridge also requires space above and below for ventilation, so I wasn't sure if I reducing air space was a good idea or not. Jury is still out for me on that one.
The faucet I use was discontinued shortly after I bought it, which is unfortunate because the black and stainless is a good look. Aesthetically this is pretty close to what I have: amzn.to/3qHli8E Thanks for following along!
Water tank - you mention a company making similar tanks out of PVC now, but you didn't mention a name, and I don't see any links for that. Can you share? Thanks!
How did you route your Spar exhaust to the drivers side?? Your original Espar vid has it out PS and I know you rerouted it after installing the PowerSteps, could you post some photos or a vid or that?? Thanks so much for all your informative vids!
Hi, I have a photo of the re-routed exhaust here: ourkaravan.com/espar-s2-d2-install/ It's really easy on a 2WD Sprinter, not so much the "4x4." I had to purchase an additional few feet of exhaust hose since I had cut the original to go out the passenger side. Thanks for the kind words! -Ken
This one is made by RB Components. It’s good but a little baggy fitting. If money is no object get the Rolef from Canada. It’s around $900, about $300 more than the RB.
One has to be careful with those check valves in the sink drain system. If any food material goes down the sink, those will clog. Happened to me all the time...
Hi Ken, I’m completely new in this camper conversion domain. Your video’s helped me a lot to get a better understanding of the several phases to convert a Mercedes Sprinter van. What I still don’t understand is why most (if not all) of you start from a cargo van instead of a Mercedes Sprinter “Tourer” version with factory windows. What am I missing? Thank you.
It's harder to buy a Crew Van (crew has window and one bench seat) than a Cargo van. MB doesn't really sell the Crews or Passenger with 4x4 unless you do a custom order and that takes a long time.
@@rafski123 Thank you Raphael. But the Tourer is perfectly suitable for a van conversion, right? No downsides to the factory windows or anything to hold back if you could get one?
@@stevenvdbroeck Honestly, I never heard of the Tourer until now, perhaps it's not sold in the US? I see it on the international MB website, but not the US one.
@@stevenvdbroeck For my build I don't want windows, they are bad for insulation and also don't need to look outside, so I don't see a need for windows in my van.
Steven-not sure what a tourer is but I’m guessing it’s a passenger van. I would prefer having full windows like the passenger van, however many do not start with this configuration because it costs quite a bit more due to the rows of seats, different suspension (which I ordered for mine), and the interior trim work. If it weren’t for the significant price difference I would start with a passenger van. The more windows the better. The downside is the passenger version has roof top ac that limits what you can do with the roof.
P.S. the build alone did not cost $70,000--that price includes the cost of the brand new custom-order Mercedes Sprinter van as well.
After watching van builds for 10 years. This is still one of the ones that stand out for quality and design. This is now my favorite kind of video. What works and what you would do differently.
I'm 95% complete with my van build. I hope I am as pleased 5 years from now as you are. 👍
That’s a huge complement, thank you so much!
Great follow up Ken. Your videos inspired me to do my own DIY and your ideas are still influencing me. I changed my mind on the fresh water tank and plan to use 4- 5 gal Gerry cans (with your quick disconnect/check valve system) instead of one big tank. Two vents installed, two windows installed, flooring installed and this weekend two flarespaces will be installed and I will finally be ready to start with the inside cardboard mock up to be followed by 8020. I've watched 100's of van DIY videos and still come back to the Ken method. Thank you for your guidance, instructions and inspiration.
Super nice complement, thank you! When using a number of jerry cans I would recommend doing your best to keep the supply lines to each tank close to the same length. If using four tanks, perhaps two sets of T's might be one solution. It's amazing how evenly the tanks empty in unison.
Let me know if you need anything and thanks again!
You're absolutely right about the lack of follow up videos. Yours is the only one I've seen, and it's so important! A great van build by the way.
Glad it was helpful, and thank you!
You are such a good teacher, Ken! I've seen your initial van build and it was so advanced for its time. I was impressed with how you patiently and with humility, explained it all to us neophytes. It was therapy for you, and also for us watching it. It is a work of art even today, way ahead of its time. Every detail shines. You did a fine job helping yourself and your daughter get over the trauma.
I lost my adult daughter to cancer in Jan 2020 to cancer. I try to lose myself in van builds, exploring, creating. and distracting my brain from that horror. It is enormously therapeutic to listen to you, the quiet voice of reason and technical perfection. You have touched so many. In every video I learn a lot.
Marmoleum - a modern take on linoleum. Bio friendly, durable, easy to install and maintain. Its making a comeback. Van building relies heavily on knowing all the raw materials to use. Research is exhausting. Thanks for this shortcut.
Smart Batteries - Lithionics is the best Lithium brand to get at present. It has its own BMS. Very pricey, but very reliable. Batteries and tires make or break your van.
Smart idea about multiple fuse distribution centers. I have to redo my old Class C and its a scary thought. Now I know that I can install several of these fuse boxes and not have to run wire all over!
If you want to know best materials out there, watch the Humble Road Videos. George started commercial van builds and has weekly videos and tips that are so rich in content. He also swears by Thinsulate and Mass Loaded Vinyl for sound deadening. Typically on the ceiling, for max insulation, he uses MLV first, then Thinsulate with white side facing interior, then Reflectix bubble wrap over the Thinsulate. Apparently, when the fluffy side meets the Reflectix, it acts as an air barrier and thermal break. Then he installs a floating ceiling in sectional panels that are removable. Wiring is accessible due to the removable ceiling. Clever, isn't it?
I remember when you ordered that double sliding chair that opens into a bed. The best one that I've seen so far is the very recent Kabe Affinity van. This van was designed by a Polish guy, and launched by Kabe, a Swedish company. It was being shown in Caravan Salon in Dusseldorf. There is a double passenger seat much like yours. It unfolds into two single beds! I was so blown away. I watched it unfold 10 times to memorize the mechanism. Two separate single bunk beds from a passenger double seat. Your daughter will love it! It also has an expanding garage with a rear double bed on linear actuators. Fun stuff.
Thanks for sharing! Glad to see you back in action. Greetings from California!
I finally found the double bed seat you mentioned, that is totally wild, thanks for sharing that.
I can’t thank you enough for the kind words, means a lot. I am so sorry to hear about your loss. Life sure provides twists and turns and all we can do is try and adapt and make the most.
I wish you the best of luck and hope to see you out there sometime.
One of the first van build video series I watched. Still the best and most informative!
Thank you Peter, I really appreciate the kind words. Thanks for following along all of these years!
In 2018 my wife and I purchased a brand new Sprinter to convert. Your videos were a god sent. Although we went the route of Adventure Wagon kit and Trail Kitchen chuck box we followed your practical approach when approaching fan, window additions, swivel seats, etc. We finally sold the van in 2021, which we missed almost immediately. Fast forward to February 2023 and we're back but in this case we purchased a 2019 Metris with a poptop that fits in the garage even with the 2" lift kit. Currently working on the basics sound deadening, insulation, house battery system and most important a gas fired espar. Yes a much different animal but in many ways the same except smaller. Thanks again for all your insights and help. Wishing you and family all the best!
Thank you very much for the kind words, and wishing you a ton of fun in the new van! (I don't think I could go one summer without mine!)
Don’t even own a van and have followed since the beginning. Love the videos and glad everything has worked out. Safe travels.
Ha, that's neat. Thanks for following along!
Hey Ken, Am about 2/3 through a short wheel base Sprinter van build. Like you and others, I have spent countless hours online, researching thousands of sites, what to do and how to do it. Hands down, your site is superlative! The best I have seen. You inspired me to use 80/20 although I am a woodworker. Marrying the two skill sets has paid off hugely. Keep up the excellent work buddy! Alan
Thank you Alan, that's a huge compliment! I hope you enjoy working with the 80/20 as much as I did. I like the aesthetic, but also the weight savings, strength and adaptability for future add-ons.
Thanks for posting this video. There are plenty of installation videos but not much of long-term reviews. That's what I'm looking for. Enjoy!
Glad you found it helpful!
Ken you are certainly a craftsman and it is proof after five years. Also an excellent videographer willing to share your knowledge. I’m about a 1/4 into my build. Previously I had a teardrop trailer. Well made but the builder applied a lot of marine varnish to its interior plywood wall cladding. After four years of owning it, the teardrop continued to off-gas VOCs. So I am attempting to construct my van with green materials. I used for Marmoleum for my flooring and it is amazing. Really like it and would recommend it to anyone. It is tough too. Anyway, I appreciate your follow up video. Unlike 90% of the factory RVs which are engineered to fail, your’s is a testament of what should be an industry standard. Good on you I vote yay.
Thankfully there is a wider range of environmentally friendly products available now than when I started on my van. The only off gassing I still occasionally get is from the rubberized coin flooring when it’s exposed to direct sunlight. Thanks for the feedback on the marmoleum.
I truly appreciate the complement and wish you the best of luck on your build!
Thank you for this great review of your build longevity! 🙂
Awesome build Ken! I used 80/20 in my Astro because of watching your early videos. If I do a rebuild I would like to install the Rock & Roll Bed. Happy Trails
Thank you Dan, I'm super happy with how it all turned out. :).
My upholstery work in my van and headliner shelf were done spending countless hours studying your channel, and I often get complements on how professional it looks. Besides the massive savings from doing it myself, the satisfaction makes it so much sweeter. I can’t wait to execute more of your innovations with my own twists in my 2021 sprinter
Super nice complement, thank you! This material is what the big boys use, and I'm super happy I went this route.
Indeed, you have to be proud of this van, because of all the meticulous work and research you did, it is one of the best van out there. 😎
Aww thank you!!
Thanks for posting this. I have learned so much from your original videos. I, and so many other appreciate your videos. I am doing my water system just like yours now. Take care.
Thank you so much for the kind comment....good luck with the install and happy travels!
I used Marmoleum and it was getting scratched up almost immediately. I wanted to love it, but just couldn't. So I got a large sheet of marine coin vinyl flooring and made a large removable mat for the entire floor and I love that. Super durable and also has more traction for my dogs.
Thanks for sharing, that is disappointing to hear. I suppose every product choice has it's downsides. I have coin vinyl in the rear of my van and while it is durable, it's downside is difficulty of sweeping/cleaning. I'm still happy with it though. -Ken
Hi Ken, I watched you from the start and George from Humble Road. I'm was sold on using 80/20 from you two. I have to admit that I'm in the same boat when it comes to working with wood. Anyway, awesome build and I'm glad you and your daughter are enjoying the rewards. 🙂
I credit the aluminum framing for giving me a much nicer and safer (and lighter) build than I would have had using wood. Thanks for following along and good luck!
Absolutely awesome job!!! Really appreciate your creativity and most importantly your honesty on thé whole project. She’s a real beaut💯
Thank you, I appreciate the positive feedback!
Awesome how well your build has stood up. I watched your build videos & you are far to modest, your patience, your research/ planning, & execution is some of the best I've seen even up against the pro builders. Your videography & explanations were super well done & anyone contemplating a build would be wise to subscribe & watch each of your build vids Big Thx !!
Super nice complement, thank you! I’ve really enjoyed sharing the process over RUclips , and hope to meet more people like you on the road!
Still my #1 build if I was under 6’ tall. Great update and will be my first go to video series when I start my build. Thanks!!!!
That's a huge complement, thank you!
I watched when the build was going on. You should be proud Ken, it’s a beautiful build and has held up great. I’ve seen several vans that were built with wood framing needing repairs after 2 years or so. Thanks for the update.
I’ll let you know if my aluminum framing warps, absorbs water, splinters or attracts termites. 🤣
Thank you for the kind words. 😀
@@ourkaravan 👍✌️
Well done on doing a proper build. I constantly find myself commenting on builds that give no consideration to vehicle dynamics and collisions/accidents. Most builders don't have a clue and are creating death traps. There are some good videos on here showing factory built campers in collision testing which may scare you. Not a magnetic knife holder in sight which makes a change. Even those damn magnetic spice holder tins would become projectiles in an accident. All budding van builders need to watch this video and appreciate the thought that has gone into it👍
My wife was an biomechanical engineer that worked evaluating forces in crashes--and you're right, those RV crash videos are super scary. The magnetic knife rack thing I will never understand--totally agree with you!
Plumbing system worked like a charm. Going on 3 years now. I use one 7 gal container for fresh and one for grey under the counter. These check valves are money!
Awesome, thank you for the feedback!!
@@ourkaravan What company makes the 11 gal tank for mounting under the van that you mentioned in the video?
www.nwconversions.com/product/11-gallon-sprinter-undercarriage-water-tank-sp-uc-11/
It works with the Amp power step I have too.
Thanks Ken, for the 5 yr update. Your site was the one that inspired me towards DIYing our 2016 van. We are still DIYing and are enjoying it along the way as well. I don't know that I have a ton to add but just my contribution of appreciation for your sharing the quality work that your have done. I just wish I could get 100% comfortable drilling holes in my van, lol, lol.
Drilling holes in the van was never a favorite of mine, but it does get easier. Thank you for the kind words and I wish you many years of enjoyment from your van!
Hi Ken
Thx for doing a self review of wear and tear. I think the overall product was better than many pro builders.
I built my sprinter 170 van in 2018
I wonder if you kept the DC to AC inverter up front - to send ( ac power thinner wire ) to the charger at the rear then AC to DC again?
I liked this idea - wondered if it worked?
That's a huge complement, thank you. I do still have the forward inverter. I have only used it once for an extended period and it did great. Solar has met 99.9% of my needs, so I simply haven't used it much. The infrequent use is why I went this route vs a more expensive battery-to-battery (B2B) charger and all the associated heavy gauge cabling. If you forsee the need to regularly charge via alternator, a B2B is probably a better path.
Best video I’ve seen on the actual outcome and use of a van conversion! Thanks for your candor.
Thank you, glad you enjoyed!
What a wonderful job you've done and this video is just full of valuable information.Thanks for info and keep up the great work.
So nice of you, thanks Mark!
Ken, you da man. I love your van. Happy Travels.
Haha, thank you! Safe travels to you as well!
Watched your original build years ago and particularly liked the 80/20 aspects. So much that I am putting them to use. I am finally starting my build on a 2020 170 crew 4x4. Couldn’t be more excited. Thank you.
That’s great, not much to go wrong with aluminum. 😀. Good luck and take care!
Great idea for follow up !! I'm 80% done... and just about to do my walls !!! Cheers
Congrats, and good luck!
Thanks for the review. We’re hoping to build our van in the near future, and I look forward to watching rest of your videos. 👍
Thank you, and welcome to the channel!
love the water system and appreciate the research on the products you found for it!
Thank you, glad you like it!!
Welcome back Buddy we missed you! Love your videos
Thank you!!
Your build is awesome! So awesome to see how well your design, materials, and craftsmanship has held up. Cheers.
Thank you thank you!!
Hello from the Seattle area. I found your channel and website this morning and it has kept me from my weekend chores! :) Really enjoying it as I think about embarking on a conversion myself. I am also a cruising sailor as well and enjoyed the comparison on your website to a cruising boat. What do you do for toilet needs?
Hey Peter, vans are a good distraction in an lot of ways, especially chores.
I use a Therford 320p porta potty. It works great for our needs.
I saw that you used 1.5-inch 80/20; would you do these cabinets in 1-inch 80/20? What was the reason for using the 1.5-inch 80/20? I am building my van and like the 80/20 features, but I would love to use the 1-inch 80/20 to save space. Thank you for great videos!
I built one cabinet out of 1 inch and since have moved exclusively to using 1.5." While the 1" is definitely better than wood, the fasteners (usually 1/4-20) used with the 1" are far smaller with considerably less strength than the 5/16" fasteners used on the 1.5." The larger material has more profile styles available, more fastener options, and more accessories such as pivots, hinges, etc. You can recess 1/4" plywood into the 1.5" too. Just a few of the reasons. The only place my cabinet "loses" space is the dividers between the drawers. You could use another material there to save space if you wished.
Thanks for the follow up, still waiting for my van but when it's finally here many tips from your build will be a tremendous help
Congrats on the inbound van and good luck!
Just loved watching your build, attention to detail plus the in depth videos and knowledge sharing during the whole process. So it was just fantastic to see the update, thank you.
Thank you, much appreciated!
The only one I seen someone use ENT Conduit... As I use that stuff in my RV build...Blue for 120 volt, Orange for 12 volt wiring...As these are vehicles. Not a damn house.. That does not see Vibrations, Flexing, Chemicals around the wiring etc...So you should wire them with that in mind....Not to mention easy to service or add wiring later......
Hi Ken
Thx for doing a self review of wear and tear. I think the overall product was better than many pro builders.
Did you keep the DC to AC inverter up front - to send ( ac power thinner wire ) to the charger at the rear AC to DC again?
Yes, the forward AC inverter is still there if I need it. I don't need it very often but it's nice to know I have a backup. Thank you for the kind words!
Yea! Glad to see you back at it, and this is a great topic Ken!
Thank you Peter, I always appreciate the support!
Thanks for the update. I've been viewing your channel for my current build on a 170 Sprinter. Your videos and details have been so helpful and encouraging. Happy Trails and God Bless!
Thank you Perry and good luck 👍
Which company makes the 11gal tank you mentioned??
Love you videos. You inspired my galley and cabinet build! Thank you.
Nice, I hope your project was a success! Here’s the 11g tank: www.nwconversions.com/product/11-gallon-sprinter-undercarriage-water-tank-sp-uc-11/
Always love seeing your videos, been watching your channel since 2017
Awesome, thanks for following along!
I see you have auto plates, not commercial - did you have any issues at DMV to change them? Do you know how much you save in DMV fees with those? Great vid, love your quality and want to build the same headliner shelf next.
Hi, full details here: ourkaravan.com/register-commercial-van-as-camper-van
you can be justifiably proud of your setup. so many great ideas and thought processes. thanks for sharing. really enjoy watching your videos. While the aluminium sections are great for keeping down weight they can be prohibitively expensive here in Australia. There are other 'non wood' options, we have been testing for some time.
I’d love to know what you find. I’m super interested in alternative products that are lighter, stronger and more sustainable.
Thank you so much for the nice complements. 😀
Looking for a van, either already built, or to build. Glad I found this youtube! Will subscribe
Good luck in your search and thank you!
Another great video.
Not much wrong here.
2016 seems like so long ago and you were on the leading edge with this build.
High quality build anyone can duplicate if they have your dedication.
I would have watched regardless, but maybe the title will net some additional viewers and potential business.
Ken, if you ever need some content, you could always share some additional trip videos. Enjoyed your past vids. They don’t need to be personal. Just where you went, what you saw and how capable your 2wd sprinter has been to get you there.
I’ll be interested to see how the van changes to accommodate your kiddo as she grows.
Pop top?
All the best!
Thank you! I don't plan to stop making videos...I really enjoy the process. I will continue to share our travels as well as upgrades and happenings with the van.
While not detailed on this video, the cabinet adjacent to my daughter's bed slides open and it's padded at the same height as her bed, so her feet can extend all the way to the wall of the van. As long as she doesn't get over 5'10" we are good! :)
Thanks for the comment and for following along! -Ken
Great work…I am basically duplicating your build…including factory headliner…where did you source the connectors with check valves for your sink tanks ? Thanks ! Great quality work right here 😊
Hi, the sink water system and parts are detailed here: ourkaravan.com/van_water_system/. Thank you for the kind words, and good luck!
I value your five-year update on things. Have watched most of your YT vids multiple times, so you indeed have influenced my thinking! Yes, maintenance is seldom discussed. Last year I bought six of the five gallon jugs to use, but then decided otherwise because I was not grokking how to daisy-chain them. I've been leaning toward the Humble Road approach of installing an eight-inch access portal in the top of the water tank for viewing and clean-out. Those jugs have gotten mighty expensive so the tank would have been a less costly approach. Now that I saw the check-valve I understand how to use it. My only concern, then, is that for water we would drink, I would run that through filtering and UV, still doable with your system. We could do the two up front like yours and keep any additional (as needed) in the garage. I'm looking at using smaller cross-section extruded aluminum. Mocking that up soon.
Your plan sounds good, the advantage of course of having a tank under the van is less space taken up inside, but it can freeze, harder to fill in remote locations and there’s the cleanliness issue. What I don’t get about the access port up top is you would need to drop the tank every time you want to clean it. I open up my containers and dry them completely when not in use.
And yes you could use filtration with my setup.
Good luck with your build and thanks for watching!
Well done ! thanks for showing !
Thanks for a unique perspective and your well tested recommendations.
Thank you for watching!
With the lizard skin spray, is it pointless to spray it on the beams that stick out from the van right? Seems like you can save by just spraying it on straight sheet metal? Also do you think it does much to spray it on the floor? I’ll be insulating the van with thinsulate and poli board on the floor
I'm not sure if it's pointless, but those support ribs are either spot welded or structural adhesive glued to the roof panel, so it's going to conduct some heat through. I did spray mine, but I taped off the ribs that face the floor so as to not create a problem when I reinstalled the factory headliner that uses plastic pushpins.
I think spraying the floor may have very minor benefit to retaining heat, but I would say not nearly so much as a roof or sides of the van that subject to direct sunlight. -Ken
Thank you for the video...and all the info you share. Around minute 13:30 it shows gray recess inserts for the black switches on the pillar. Where did you find them? Thx
Hi, these inserts come on Mercedes crew vans, but not cargo van. I imagine you can order them from MB.
Lovely van build!! Greetings from sunny Jamaica.
Why thank you!
I am an amateur woodworker. For a person like myself who has some (limited) woodworking skills would you still suggest the use of aluminum extrusion for cabinets etc.?
For me the aluminum allowed me to build a relatively lightweight, adaptable, strong (safe) and beautiful cabinet without the woodworking skills required to pull that off with an all wood cabinet. I would absolutely do it again even though my wood abilities have improved a bit.
I am curious, did you used Lock Tite on the 80/20 anchor fasteners? I saw that you used it on the all of the other connections but I didn't see it on the anchor fasteners. And if you didn't, did any of those come loose over the 5 years? Thanks for your detailed videos and site!
Using loc tite is recommended but I did not. I’ve had a couple that loosened over the years, which the loc tite would solve, but it hasn’t been enough of a problem for me to back all of the fasteners out to do so.
What a circus with the battery!?! Talk about bleeding edge technology. Lithium was new to me and although I've not anything happen like you I've still had some "do I have a matching pair of $2,500 boat anchors" moments. Once I learned that's BMS' didn't like the inrush of the inverter and how to pre-charge the inverter it's been smooth sailing. Cheers!
I mentioned the need to pre-charge the inverter because I often learn just as much in the comment section as I do from the video. Hopefully I will save someone else a week of stress while wading through shaky support from both the battery and inverter sellers trying to find the person who actually knows what they are doing. None of the documentation that came with Victron inverter or the LifePo4 batteries mentions the need to pre-charge.
I guess that might be one advantage of my old school external bms, but thanks for sharing this information.
Wow… first time I watched your channel. Great review of components and loved the electrical tips and window reviews. Also your water advice can be used for campers as well if they need to fix water leaks to the fresh water tanks.
Thank you and welcome to the channel!
I would recommend instal Webasto under the van I made specet stainless steel box for it and what you win les noise. And space. All else is super made :) I planing to sell my van and get like yours sprinter :)
Nice!
Thank you
Thanks, Ken! Your 5 year review already has me thinking in new directions.
What are the top 3 noise makers inside your van when driving?
Were they noisy from the start or did they get louder over time?
And, last, does that CRL vent window (the one that doesn't close flush) whistle?
Hi, I have a couple of rattles but not sure where they are coming from. I believe one is in the sliding door. The other I think is the refrigerator but it’s hard to tell. The van is fairly quiet on most roads but the rattles do come out offroad.
The crl window does not whistle, thankfully. Thanks for the kind words!
Nice overview with lots of useful tips !
Appreciate the positive feedback!
Great video and van. I'm just starting a van build and will be using some of your van build ideas. Thank you
Good luck and thank you!
I love your setup for everything! Thanks for the great long-term follow up!
Thanks for watching!
This video and this van build is quality all the way. Very useful tips.
Thank you Annie!!
Hi, do you have a video about the rear seat and rails that you’ve used (perhaps with install), as it’s such a great idea.
PS The quality and simplicity of this video with clear communication absolutely enthuses me to go through your back catalogue - especially as you’re so seasoned. Great work!
Hi, I do have a video on the seat install. It was technically challenging since I needed support brackets to tie into the vehicle frame. I had to secure help from a friend with this one. ruclips.net/video/uqk-nkqjemQ/видео.html
Thank you for the kind words! -Ken
Great review, a valuable contribution to DIY folks.
Thank you George! You and Dave Orton were highly instrumental in my decision to use 80/20 in my build.
Hi, the link that you have goes to a webpage when you click on those to try to get more information it’s not working could you check on that and let us know I wanted to definitely get some more information on this cabinet builds and which part number you were using for the extruded aluminum thanks very much the videos are great
Hi, which link are you having trouble with? They seem to work on my end. Thanks
maaaan i love this video. so in depth all infos included. I just wanted to know what your material is called. the gray one with little "dots" in the back of your car to make the box for your electrical system over the aluminium
The flooring is called coin flooring and I got it from garageflooringinc.com. Thanks for the compliments!
how did you wire the additional fuse panels? I didnt see that mentioned in your electrical blog posts. are you just running a thicker gauge wire spliced in right before the first main due panel? or do you run it out of the first fuse panel?
I talked to Blue Sea first to see if this was advisable. The fuse blocks I use are rated for 100 amps and can be daisy-chained as long as you never pass more than that through. I calculated my max DC load at 60 amps, so I have a 60 amp DC breaker and wire to handle 60 amps passing through three linked blocks. The advantage of doing it this way is I don't have a spaghetti of wires running to a single fuse block. One is located at the battery, one behind the galley for those loads and one in the overhead cabinet to run displays, charge ports, etc, in a pass-through fashion. I hope that helps.
Now would you still use the small sliding windows in the back, or would you prefer the small RV style tilting windows that allow to be open during rain ?
Now that there are glass bunk windows that tilt open, I would probably really like those, as long as they have integrated screens. I am not a fan of the tilt-out poly carbonate windows due to the non-tinted aesthetic, but that is personal preference.
LEGEND. Keep keeping us inspired
😀😀
I'm really interested in how you covered your garage area. Looks like a plastic coin covering on wood. How did you get it to attach to the extruded aluminum?
Hi, I did a video on the coin flooring install here: ruclips.net/video/YmfWGvHsDjI/видео.html
Ditto the customer service and sporty quality on the CRL window. The glass on the flap wasn't glues flush to the hinged and had a gap in it..yet it still had a "passed" QC sticker on it!!
Thanks for the feedback, it's definitely hit or miss.
How do you replace the water with air in the water jugs when using water? There should be some way to relieve the pressure loss I would think.
There are some small threaded air vents on the water containers that need to be cracked to let air in. I’ve never had any water leak through.
LOVE marmoleum- gonna put cork under mine.
Maybe I’ll try it in van #2 😜
I was looking on your site for info on how you built your countertop but didn't see it. Maybe I was looking in the wrong place? Anyway you mentioned it was built from 1/2" plywood. A couple of questions:
#1: How did you build up the edge of the countertop? It looks to be at least 3/4" Did you add a strip of solid wood around the edges? Or a strip of plywood?
#2: Can you explain a bit about how you did the laminate? Or do you have a video about this? I looked for it but didn't find it.
Thanks.
I used 1/2” Baltic birch and a friend helped me glue a thin veneer of bamboo over the edge to make it look like solid bamboo, trimmed it flush with the edge of the plywood with a trim router, and then put contact adhesive on the top surface of the plywood and under the Wilsonart laminate. Lay a bunch of wood dowels on the surface and working from the center out, press the laminate down while pulling the dowels. I don’t have a video on this but there should be many on RUclips. I hope this helps, it all looks just as good as the day we did it.
I used 1/2” Baltic birch and a friend helped me glue a thin veneer of bamboo over the edge to make it look like solid bamboo, trimmed it flush with the edge of the plywood with a trim router, and then put contact adhesive on the top surface of the plywood and under the Wilsonart laminate. Lay a bunch of wood dowels on the surface and working from the center out, press the laminate down while pulling the dowels. I don’t have a video on this but there should be many on RUclips. I hope this helps, it has held up well.
Really appreciate you showing things after 5 years, Nice job. Some intelligent choices, like the water and others. Is it ever a problem to lift the bikes so high and secure them? So I guess you live in the Sac area?
Yes, I carry a small ikea stool in the van that I need to get the bikes on and off. From my perspective that helps make bikes more difficult to steal since the locking arm is the highest part. If a thief wants it they’ll get it, but bring up high slows them down.
I am in the sac area-glad you enjoyed the video!
I want to buy one of ur refrigerator- sink- draw cabinet system only in the reverse setup. That is to say it would be in front of the barn door with the cooking system near the door then the draws then refrigerator. This shouldn't be a problem reverseing this to my configuration would u think? How much would this cost me? Awaiting ur response! Thanks for ur time and efforts.
Hi, all of my existing galley designs are reversible. There are photos of one of the designs reversed here: ourkaravan.com/cabinet-kits/
The bamboo cabinet doors look quite good, where did you get them from? 👍
The bamboo is from the company Plyboo and I have purchased it from two separate hardwood stores in my area. Both were able to order it for me without any issues. If you live in central California I can share where I bought mine, but I would check around locally first. Thank you for the very kind words!
Is armaflex xg insulation not hydrofobic also?
Your van is looks amazing and I love your videos. I've started working a little with 8020 and was wondering why use the 15 series over the 10 series. I've noticed that the 10 series is cheaper and seems strong enough for most cabinets; however, I'm new to 8020 and it could be that there are some huge advantages to 15 series. Thanks again for all the wonderful videos.
Hi, I discuss the 10 series vs 15 here: ourkaravan.com/8020-extruded-aluminum-van-cabinets/
In short it comes down the fastener strength. If you use something other than the small 1/4-20 carriage bolts that fit in the 10 series, it’s probably fine. Anchor fasteners are very strong but very difficult to do at home, hence why I stick with 15 series.
I sure appreciate the kind words, thank you!
Awesome build - thank you for sharing these insights!
Good review, you did an excellent job and I copied several ideas from you when I built mine....
Fantastic, thank you!
As always a great, informative video. I watched all your build videos and it's good to see this follow up. Thanks
Thank you for following along for all of these years!
Great topic seldom covered by other channels.
Glad you liked it, and thank you.
Any issues with your gray water tank freezing? I moved mine inside to avoid any problems.
Guess what my van does not currently have? A gray tank...one will be coming soon.
@@ourkaravan so it just drains from sink to the ground outside? I swear I saw you put one in, must be confusing it with the video where you made your shower water tank.
If I let it, it would drain to the ground. Laughably I’ve been carrying around a 2.5 gal tidy cat container I put under the van if in an environmentally sensitive area or in an established campground. I always use environmentally friendly soap regardless. We have so little wastewater I’ve realized I really only need a 5-6 gal gray water tank, and will use the space under the van for something else.
Thanks for this video. It confirms a few choices for me.
How is your fridge working for you? Do you have extra insulation around it for warm weather camping?
Fridge is great. Some do add insulation around them, but the fridge also requires space above and below for ventilation, so I wasn't sure if I reducing air space was a good idea or not. Jury is still out for me on that one.
Watched your original build video from years ago. I plan to use your water setup; what faucet do you use?
The faucet I use was discontinued shortly after I bought it, which is unfortunate because the black and stainless is a good look. Aesthetically this is pretty close to what I have: amzn.to/3qHli8E
Thanks for following along!
u r amazing..! thank-u for yr support. Me missus and i LOVE watching yr videos.. u make us believe we can do it too...! cheers from melb Oz..🇦🇺
Love it, thank you!
What glue gun and glue were you referring to when you were discussing upholstery?
Hi, I have the process and materials detailed here: ourkaravan.com/upholstered-wall-panels/
Enjoy!
Water tank - you mention a company making similar tanks out of PVC now, but you didn't mention a name, and I don't see any links for that. Can you share? Thanks!
Northwest conversions makes the tank.
Not seeing it on their website. Just their usual wheelwell-cutout offerings?
www.nwconversions.com/product/11-gallon-sprinter-undercarriage-water-tank-sp-uc-11/
Ah ok, thank you!
How did you route your Spar exhaust to the drivers side?? Your original Espar vid has it out PS and I know you rerouted it after installing the PowerSteps, could you post some photos or a vid or that?? Thanks so much for all your informative vids!
Hi, I have a photo of the re-routed exhaust here: ourkaravan.com/espar-s2-d2-install/
It's really easy on a 2WD Sprinter, not so much the "4x4."
I had to purchase an additional few feet of exhaust hose since I had cut the original to go out the passenger side. Thanks for the kind words! -Ken
You are a reference sir. keep up the good work !
Thank you, will do!
Super helpful video! Thank you!
Nice! I may have missed it, but looks like you have some sort of bug screen for the sliding door? Not sure if you liked it or not.
This one is made by RB Components. It’s good but a little baggy fitting. If money is no object get the Rolef from Canada. It’s around $900, about $300 more than the RB.
One has to be careful with those check valves in the sink drain system. If any food material goes down the sink, those will clog. Happened to me all the time...
There are no check valves in the gray water system, only on the fresh water side, and you are correct.
Hi Ken, I’m completely new in this camper conversion domain. Your video’s helped me a lot to get a better understanding of the several phases to convert a Mercedes Sprinter van. What I still don’t understand is why most (if not all) of you start from a cargo van instead of a Mercedes Sprinter “Tourer” version with factory windows. What am I missing? Thank you.
It's harder to buy a Crew Van (crew has window and one bench seat) than a Cargo van. MB doesn't really sell the Crews or Passenger with 4x4 unless you do a custom order and that takes a long time.
@@rafski123 Thank you Raphael. But the Tourer is perfectly suitable for a van conversion, right? No downsides to the factory windows or anything to hold back if you could get one?
@@stevenvdbroeck Honestly, I never heard of the Tourer until now, perhaps it's not sold in the US? I see it on the international MB website, but not the US one.
@@stevenvdbroeck For my build I don't want windows, they are bad for insulation and also don't need to look outside, so I don't see a need for windows in my van.
Steven-not sure what a tourer is but I’m guessing it’s a passenger van. I would prefer having full windows like the passenger van, however many do not start with this configuration because it costs quite a bit more due to the rows of seats, different suspension (which I ordered for mine), and the interior trim work. If it weren’t for the significant price difference I would start with a passenger van. The more windows the better. The downside is the passenger version has roof top ac that limits what you can do with the roof.