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Camper van

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royce

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Jun 22, 2014
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fairbanks ak
Got most of the branch circuits and switches wired, moving on with plumbing.
Got the domestic water pump, expansion tank, HW heat exchanger and a good bit of the piping in.
Need to start on a water tank now.
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Royce
 

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royce

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fairbanks ak
Other than preventing environmental damage rust etc. What was your thinking when you Line-Xed the out side of a new van.

We travel a lot of gravel roads and the sprinters are known to not have very good paint.
That is the the sole reason.

Royce
 

dreamingmuscle

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Tryon Oklahoma
Love the build btw. I'm thinking of doing something similar on a smaller scale.

Started a thread about it in free parking.

But your build is way out of my class of skill.

I especially like the fold down bench seat. That would allow a few of the grandkids to tag along now and then.

I would love a off the shelf parts list if you have one for the water heating systems. And a link to the bench seat if it's off the shelf.

Thanks Glen
 

dreamingmuscle

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We travel a lot of gravel roads and the sprinters are known to not have very good paint.
That is the the sole reason.

Royce

Gotcha I had the bottom 1/4 of my truck sprayed soon after I bought it just for that reason.

I live on dirt roads and what gravel is there is brutal on paint.
 
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royce

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Love the build btw. I'm thinking of doing something similar on a smaller scale.

Started a thread about it in free parking.

But your build is way out of my class of skill.

I especially like the fold down bench seat. That would allow a few of the grandkids to tag along now and then.

I would love a off the shelf parts list if you have one for the water heating systems. And a link to the bench seat if it's off the shelf.

Thanks Glen

Thanks Glen,
The fold down seat is made by Freedman, we put it it in for grandkids too.

Sorry, I don't have a parts list for the heating system, just a sack of receipts.
I kind of made it it all up as I went.
Here is a pic of the rough schematic I started with.

The boiler was made by Espar and the basic package was supplied by Rixen Enterprises.
If you google Rixen, there is a good bit of info on their website.

Good luck on your build and let me know if there is any other questions that i might be able to answer.

Royce
 

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dreamingmuscle

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You tapped into the engine heater hoses under the hood?

I thought the system was dual heat and hot water off one boiler. So basically your hot water in the sink runs thru the floor first. I was thinking to my self that's a long run for the hot water to be running.

But slap my head, the floor system would be a bear to drain thus needs to be protected with antifreeze. And running it thru the engine block acts like a block warmer in the winter. Along with almost free floor heat while the engine is running.

Does the engine running hot water thru the boiler help heat the potable water.
 
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royce

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fairbanks ak
You tapped into the engine heater hoses under the hood?

I thought the system was dual heat and hot water off one boiler. So basically your hot water in the sink runs thru the floor first. I was thinking to my self that's a long run for the hot water to be running.

But slap my head, the floor system would be a bear to drain thus needs to be protected with antifreeze. And running it thru the engine block acts like a block warmer in the winter. Along with almost free floor heat while the engine is running.

Does the engine running hot water thru the boiler help heat the potable water.

Glen,
Yes, I tapped the engine on the inlet side of the sprinter heater core.

There's really 3 different heat sources,the diesel boiler, the sprinter engine and a 120V coil in the expansion tank.

The engine loop is isolated from the boiler loop by a heat exchanger under the hood.

So when the engine is running, heat is provided by the engine, both for cabin heat and hot water.

When the engine is off, heat and hot water are generated by the diesel boiler.

When plugged into shore power a limited amount of heat and hot water can be generated by a 120V coil in the expansion tank, that can be supplemented by the diesel boiler as needed.

Also, the pump on the engine loop is normally off, because the engine water pump provides the circulation.
The engine loop pump is only used when the engine needs to be warmed up by the boiler for starting in the winter.

Lastly, the domestic water system is isolated from the boiler loop by a double wall heat exchanger.
Yes, the boiler loop, including the floor coil will be freeze protected with glycol.

Royce
 
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royce

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fairbanks ak
Got 600 watts of solar panels mounted on the roof.
Getting close to having all the electrical complete.

Royce
 

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royce

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fairbanks ak
Wow, looks great Royce, can the panels handle hail? Just an awesome project.

Thanks Kevin,
They have 3.2mm tempered glass tops and have a high wind and snow load rating, but no mention of hail.
I sure hope so!

Royce
 
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royce

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fairbanks ak
Making some headway.
Solar making power
Fridge making cold
Cabinet doors and drawer fronts milled and hung temporarily.
Getting close to having inverter and battery to battery charger commissioned.
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Royce
 

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royce

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Got started laminating carbon fiber to the cabinet doors and drawer fronts today.
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Royce
 

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LXCam

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Now that’s just showing off Royce........and as always in a most impressive way!
 

topcok88

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Jun 3, 2013
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This is excellent! Love how you put forethought into the build process and everything is just so for a specific reason. Do you have an idea what the end weight will be?


Sent from my iPhone using The Garage Journal mobile app
 
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royce

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Got the boiler fired, feels good to be making heat.
Also got some stainless steel trim installed.
Shower and countertops next.
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Royce
 

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TTMotorsports

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Lucerne Valley, CA
When you want to get more clearance and protect the undercarriage check out vancompass.com. been installing their products for years and have a 4x4 sprinter like yours coming in next mo this of lift and a slew of items. Also did their lift a few months back on a sports mobile 4x4 sprinter. Very nice and pop top for sleeping area.

Also side note please spend some cash and upgrade to the fox shocks it is 100x better ride and improvement over stock. Every van I swap them onto say they cant believe how it rides and why they didnt do it from the get go
 
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royce

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fairbanks ak
When you want to get more clearance and protect the undercarriage check out vancompass.com. been installing their products for years and have a 4x4 sprinter like yours coming in next mo this of lift and a slew of items. Also did their lift a few months back on a sports mobile 4x4 sprinter. Very nice and pop top for sleeping area.

Also side note please spend some cash and upgrade to the fox shocks it is 100x better ride and improvement over stock. Every van I swap them onto say they cant believe how it rides and why they didnt do it from the get go

Thanks for the tips.

Royce
 
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royce

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fairbanks ak
Making some progress on the shower.
I farmed out out the fab to a friend.
It is a two piece pan that stows in the enclosure when not in use.
I'll mount the domestic water tank behind the enclosure and have storage over it.
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Royce
 

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garandman

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Boston MA / Mt Sunapee NH
Van is going to be awesome! What did you use for insulation?
In our [2006 118” standard roof] van we used Thinsulate. While other products have higher ar values, the Thinsulate is much faster and easier to install, meets vehicle flame, smoke and toxicity requirements, and is easy to stuff into every nook and cranny.

i-4MHXRxD-X2.jpg


Used closed cell rubber foam under the floor. Filled in the low spots, then another layer over it.
i-x8gQbRG-X2.jpg


i-R7GtvGh-X2.jpg
 
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royce

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fairbanks ak
That shower stall looks great Royce. Looks like you are getting close to finishing up. I hope the to do list is winding down. This is a big project.

Thanks Kevin,
Yes, the end is in sight.

Got the upholstery and mattresses ordered and hope to get the domestic water tank and countertops this week.

As far as being a big project, it feels to me like building a house again, mercy me!!!

Royce
 
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royce

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fairbanks ak
Domestic water tank and shower surround permanently installed, received the sofa cushions and mattresses, picked up the countertops this morning.
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Royce
 

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royce

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Yes, the couch is 78" long and comfortable too.
I debated on what to make the counter tops out of and ended up giving my drawings to a friend who runs a local sheet metal shop to shear and form out of stainless and he said they would just weld them up too.
I was all for that, they work a lot of light gauge ss and can do a lot better job than I can.
Thanks
Royce
 

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bradpac

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They did a great job on that sheet metal. This project is turning out really nice, a lot better than the formica and particle board in your typical RV.
 
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royce

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Glued the backing to the countertops, dressed the welds on the countertops, radiused the back splash corners and added rubber trim to them.
Also got them fastened down and the sink installed and piped.

Royce
 

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royce

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Commissioned the domestic water system and started on panels for the side and rear doors.
Also made a cup holder, the stock one did not work so well.
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Royce
 

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royce

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Worked on window trim today.
16 gauge SS
Fused on the backside.
1 down 5 to go
 

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royce

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Got 3 more windows trimmed out today, that leaves 2 to go.

Royce
 

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royce

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Been having a tough go of fusing this light gauge stainless.
Very frustrating not being able to see a tiny tig puddle anymore.

Royce
 

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royce

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Thanks Justin,
Finished up the trim on the last of the windows today.

Royce
 

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royce

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Also today,
Cut some 1-1/2" Minicell foam for window insulation/shades.

Royce
 

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