Another Moto Van Build

john.aron
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85
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7/3/2016
Location
Boulder, CO, USA
7/24/2016 6:12pm
More good progress this weekend!

Got the top end of the RMZ rebuilt and its feeling great. My back is also starting to feel a little better. I can't wait to get out next weekend and ride.

I've decided to do a 2/3 height diving wall for a whole slew of different reasons. I will put a cargo net between the top of the wall and the ceiling for added safety but with provisions to take it down when I need to haul something longer than 7'6". The dividing walls still needs the plywood front and back is but the bulk of the work is done. I'm planning on carpeting the front section, and maybe using carpet and a rubber mat on the back side.


and with some trim.

I still need to make a cap for the wall. A 4" thick carpeted beam is what I currently have in mind.

Next, I recruited my buddy Aaron to weld me up a frame to hold the tank. I scrapped some steel from an old bed frame I wasn't using.

It's a tight fit but I think this will make for a solid tank mounting.

Lastly I used some eternabond tap to fully seal the vent fan in on the roof. I wasn't super stoked on just using the butyl rubber caulking. I feel much better about it not leaking now.


This week I plan to finish the wall and start thinking about how to do the bike's tie down points. Considering using some type of chock or just making one and integrating it into the dividing wall. The thing is pretty bullet proof.

I'll also install the rear door latch so the thing stops beeping whenever I go anywhere in it.

7/26/2016 5:56am
I just bought an extended 08 Chevy Express 3500 on Saturday and going through the same exact process. I have just finished gutting it, and now there are so many ideas that I don't know where to even begin. I am planning on doing the floor, walls, ceiling and then the divider. Lots of work ahead, but I can't wait for the end result.
Homey55
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collinsville, OK, USA
7/26/2016 9:39am
Here's some more ideas...





john.aron
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85
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Boulder, CO, USA
7/26/2016 9:52am
Homey55 wrote:
Here's some more ideas... [img]https://p.vitalmx.com/photos/forums/2016/07/26/144758/s1200_f39287950cd1a18a3ea6b7c2709bdfb2.jpg[/img] [img]https://p.vitalmx.com/photos/forums/2016/07/26/144759/s1200_fd181b828ac2506199f4711847d44191.jpg[/img]
Here's some more ideas...





Wow - That. Is. Perfection.
1

The Shop

olds cool
Posts
4230
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1/17/2010
Location
Claremont, NC, USA
7/26/2016 10:49am
That bear should feel right at home here on Vital!Tongue
1
7/26/2016 1:31pm
I just bought an extended 08 Chevy Express 3500 on Saturday and going through the same exact process. I have just finished gutting it, and now...
I just bought an extended 08 Chevy Express 3500 on Saturday and going through the same exact process. I have just finished gutting it, and now there are so many ideas that I don't know where to even begin. I am planning on doing the floor, walls, ceiling and then the divider. Lots of work ahead, but I can't wait for the end result.
Do a search of motovans on vital and you will get several threads with lots of great pics and ideas. Lots of guys on her with some creative minds and some neat setups.
Boarddesign
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1112
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12/13/2010
Location
Fallbrook, CA, USA
7/26/2016 4:03pm Edited Date/Time 7/26/2016 4:05pm
I had this bed made last week, it folds up to make getting gear or other things easier.. Both front and back portions of the bed...
I had this bed made last week, it folds up to make getting gear or other things easier.. Both front and back portions of the bed open also.










Don't mind all the crap in here, I moved to Carlsbad last week and haven't cleaned it out.
john.aron wrote:
Where did you have that bed made. It looks pretty perfect for what I have in mind.
I actually should have said "I just had this folding mattress made last week". I made the bed then bought foam / material that matched my seats and took it to an upholstery shop. I told him where it needed to fold and whatnot then he stitched it up. Earlier in this thread I showed how I built it.
CarlinoJoeVideo
Posts
7517
Joined
11/30/2013
Location
Portland/Los Angeles, CA, USA
7/26/2016 4:07pm
Here's a few more photos from my build to keep this thread alive!
This was while I was Making a small kitchen setup, stores my solar on the bottom. 2 panels on the roof. Enough to run 2 fans and 4 lights. Has 2 power plugs and 2 USB ports.





plowboy
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Location
Norwich, KS, USA
7/26/2016 4:51pm
Pretty crafty fellas around here.
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO, USA
7/26/2016 9:10pm
Got the wall finished tonight! Loving it! I realized I can bring my shop light out to the driveway, too. Should be able to get a lot more done after work now that daylight isn't a factor. I'll post some photos in the morning. At 10pm I'm still making too much progress and having too much fun to stop!
7/26/2016 9:38pm
john.aron wrote:
Got the wall finished tonight! Loving it! I realized I can bring my shop light out to the driveway, too. Should be able to get a...
Got the wall finished tonight! Loving it! I realized I can bring my shop light out to the driveway, too. Should be able to get a lot more done after work now that daylight isn't a factor. I'll post some photos in the morning. At 10pm I'm still making too much progress and having too much fun to stop!
Be careful or it will be 3am before you even realize it.Cool
burnside
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6/17/2009
Location
London, USA
7/27/2016 5:20am
Love interesting, positive posts like this.
Even if they do make me green with envy. hahaha
john.aron
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85
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7/3/2016
Location
Boulder, CO, USA
7/27/2016 9:00am
burnside wrote:
Love interesting, positive posts like this.
Even if they do make me green with envy. hahaha
Haha I have to keep ya'll engaged with suspense!
john.aron
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85
Joined
7/3/2016
Location
Boulder, CO, USA
7/27/2016 9:11am
I got a lot done last night. I'm super happy with how this came out. I think it looks clean and its super strong. It also will let me still carry full sheets of plywood, surf boards and other longer items.


I have a universal mount showing up tonight that I'll install and depending on how the bike sits, I'll figure out the exact dimensions of the railing that will top the wall.

To anyone contemplating doing their own moto-van, I have to say it's an absolute blast to work on this thing. I'm going to be kind of bummed when I eventually finish it. As a caution though, I feel I need to say that you really need to be able to think through the workflow and to not finish or even design things out of order. I don't do a lot of drawings or written plans because I prefer to just work things as they evolve, but it could be really easy to cause a lot of frustration if you get out of order.

Without any major surprises I'll bring the moto-van on its first trip to the track Friday through Sunday. Really just hoping my back cooperates.
john.aron
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7/3/2016
Location
Boulder, CO, USA
7/27/2016 9:16am
Oh and just in case you want to hear what a moron I am...I realized that the 'right rear door open' alarm that I was getting was NOT due to the back door. It was tripped by the front/mid door on the passenger side. It was tripped because the plywood panel I cut for that door was interfering with the hinge Blush When the rear cargo door is open the alarm is 'cargo door open'...Did I realize this before I bought and installed the $200 latch for the cargo door? Of course not. Oh well... I think they will let me return it. I did spend the first two hours last night figuring all that out. Anyways I relocated that panel a few millimeters and all is good in the world again.
1
Markee
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3665
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4/15/2013
Location
Suffolk, VA, USA
7/27/2016 9:49am
John good work man!

If you are ever looking for a passenger or drivers seat swivel to open up your sleeper area, I took the gamble and ordered on from northern tool (not rated for road use) Let me tell you the thing is heavy duty and works great:

http://www.northerntool.com/shop/tools/product_200487875_200487875

Added one to my passenger seat in my 05 sprinter.

CarlinoJoeVideo
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7517
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11/30/2013
Location
Portland/Los Angeles, CA, USA
7/27/2016 10:00am Edited Date/Time 7/27/2016 10:02am
Looking awesome!

Let me add to the swivel seat comment, it's a game changer for a place to sit and gear up! I put one in my sprinter and use it everyday riding.
john.aron
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85
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7/3/2016
Location
Boulder, CO, USA
7/27/2016 11:13am
Looking awesome! Let me add to the swivel seat comment, it's a game changer for a place to sit and gear up! I put one in...
Looking awesome!

Let me add to the swivel seat comment, it's a game changer for a place to sit and gear up! I put one in my sprinter and use it everyday riding.
Markee and Joe - That is tempting... I'm not sure my seats would be able to swivel though... I think there will be interferences, especially to the center console box. I might look into it a bit though. I'm also pretty sure that the bed is going to take up that entirety of the space behind the front two seats, so maybe there wouldn't be any leg room anyways if it did swivel.

Two comments about the advantages of the half wall:
1) I can go from the drivers seat to the cargo area without leaving the vehicle. So no real need to be able to change in the front section.
2) If you ever have a lock/latch malfunction on the cargo door (*cough* this guys *cough*) it's really nice to be able to still get into that compartment to either open it from the inside or to disassembly the latch and force it open. Had I built a full wall and then had the latch malfunctions that I experienced last night (from uninstalling and incorrectly installing the new one the first few times), this thread would have had a less enthusiastic feel this morning...
john.aron
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85
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7/3/2016
Location
Boulder, CO, USA
7/27/2016 11:20am
Let's talk about power washer setups for a bit...

The tank is going to be under the bed with a pump. The question is where to have the water exit. The two choices are 1. under the van, coming out around the fuel filler section OR 2. to run the hose inside the vehicle directly to the power washer.

The advantages of 1 are pretty obvious... having water outside, shorter run, less possibility of leaks etc but the disadvantage is having to load and unload the 50lb washer every day and potentially having to load it back muddy if it ends up sitting in water or dirt.

The advantages of 2 are that no hookups every day and no loading or unloading. The disadvantages include filling the van with exhaust fumes (its gas), more potential for leaks, no convenient water spout on the exterior.

Right now I'm leaning towards option 1. but I'd like to hear it if anyone has any thoughts.
hdhp
Posts
15
Joined
4/21/2016
Location
Utica, MI, USA
7/27/2016 2:06pm Edited Date/Time 7/27/2016 2:11pm
I have following this build for the last couple days! (I have lots of time lol, cuz I just had knee surgery)
Awesome Build!!! Let me tell you, I have owned an enclosed trailer, Box Van and a Chevy 3/4 ton cargo van to haul my bikes. You made the right choice with this van and everything you have done to it! I really like the 1/2 wall!
One suggestion.. Keep the outside "Plane Jane" and a good alarm system. That will keep the looser's in life away from your stuff. I can tell you work really hard for what you have! I made the mistake of putting nice wheels on mine 3/4 ton van. Good thing for insurance!
Once again Awesome Moto Van!!

HDHP
john.aron
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Boulder, CO, USA
7/27/2016 2:34pm
I like the graphics and seat cover, the blue looks great on orange
Woah I just saw that you're from Millbury, MA. I grew up in Grafton, haha!
john.aron
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Boulder, CO, USA
7/27/2016 2:38pm
hdhp wrote:
I have following this build for the last couple days! (I have lots of time lol, cuz I just had knee surgery) Awesome Build!!! Let me...
I have following this build for the last couple days! (I have lots of time lol, cuz I just had knee surgery)
Awesome Build!!! Let me tell you, I have owned an enclosed trailer, Box Van and a Chevy 3/4 ton cargo van to haul my bikes. You made the right choice with this van and everything you have done to it! I really like the 1/2 wall!
One suggestion.. Keep the outside "Plane Jane" and a good alarm system. That will keep the looser's in life away from your stuff. I can tell you work really hard for what you have! I made the mistake of putting nice wheels on mine 3/4 ton van. Good thing for insurance!
Once again Awesome Moto Van!!

HDHP
Haha glad you're enjoying the thread. I have a feeling the next stage is going to be the most interesting. A lot of parts are sitting at my front doorstep in UPS packages as we speak.

And I agree regarding the halfwall... I went back and forth between a full wall and no wall several times and this is just such a better option for how I plan to use the van.

I appreciate the advice on keeping it boring on the outside. I agree 100%. My goal is to be able to park this in any industrial park at night and not look out of place.

If i could just figure out this pressure washer setup...

hdhp
Posts
15
Joined
4/21/2016
Location
Utica, MI, USA
7/27/2016 4:09pm
Are you opposed to using a old school 55 gallon plastic drum tied to a dolly?
You fill it at the track, lay the dolly down in the back of the van, gravity takes over and u don't need a helper pump.When you are done stand the drum upright and be on your way... I have used this set up in my 3/4 ton van and trailer. But my box van had two 60 gallon tanks mounted underneath. Now that was the shit!!

HDHP
7/27/2016 4:09pm
hdhp wrote:
I have following this build for the last couple days! (I have lots of time lol, cuz I just had knee surgery) Awesome Build!!! Let me...
I have following this build for the last couple days! (I have lots of time lol, cuz I just had knee surgery)
Awesome Build!!! Let me tell you, I have owned an enclosed trailer, Box Van and a Chevy 3/4 ton cargo van to haul my bikes. You made the right choice with this van and everything you have done to it! I really like the 1/2 wall!
One suggestion.. Keep the outside "Plane Jane" and a good alarm system. That will keep the looser's in life away from your stuff. I can tell you work really hard for what you have! I made the mistake of putting nice wheels on mine 3/4 ton van. Good thing for insurance!
Once again Awesome Moto Van!!

HDHP
john.aron wrote:
Haha glad you're enjoying the thread. I have a feeling the next stage is going to be the most interesting. A lot of parts are sitting...
Haha glad you're enjoying the thread. I have a feeling the next stage is going to be the most interesting. A lot of parts are sitting at my front doorstep in UPS packages as we speak.

And I agree regarding the halfwall... I went back and forth between a full wall and no wall several times and this is just such a better option for how I plan to use the van.

I appreciate the advice on keeping it boring on the outside. I agree 100%. My goal is to be able to park this in any industrial park at night and not look out of place.

If i could just figure out this pressure washer setup...

Awesome build man. I've been following this closely as I'm currently looking for a van to start my own. I had an idea toward what I was going to do with the pressure washer and that's to unbolt the motor and pump from the frame and bolt it right to the back corner of the van hopefully with the exhaust facing out the door and run the water directly to it. My old boss had his set up like that in his box truck and it worked great
MR. X
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6913
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Location
North Tonawanda, NY, USA
7/27/2016 4:26pm
I love seeing moto van builds, its not just enough to have a good idea ,you then have to construct it . I always wonder why nobody builds flip up shelves or tool holders into the doors to provide a place to put shit on when you're working on the bike between rides.
Zaugg
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1083
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Location
Not California, CA, USA
7/27/2016 8:57pm
For the love of god please keep this thread going!!!!

SOOOOOO AWESOME
john.aron
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85
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7/3/2016
Location
Boulder, CO, USA
7/27/2016 9:45pm
hdhp wrote:
Are you opposed to using a old school 55 gallon plastic drum tied to a dolly? You fill it at the track, lay the dolly down...
Are you opposed to using a old school 55 gallon plastic drum tied to a dolly?
You fill it at the track, lay the dolly down in the back of the van, gravity takes over and u don't need a helper pump.When you are done stand the drum upright and be on your way... I have used this set up in my 3/4 ton van and trailer. But my box van had two 60 gallon tanks mounted underneath. Now that was the shit!!

HDHP
Yeah definitely opposed to that, haha. I did the math and theres no way you're going to get the 45psi input pressure that the washer wants. It may work but its a hack and besides, I already bought the pump Laughing
john.aron
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85
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7/3/2016
Location
Boulder, CO, USA
7/27/2016 9:46pm
MR. X wrote:
I love seeing moto van builds, its not just enough to have a good idea ,you then have to construct it . I always wonder why...
I love seeing moto van builds, its not just enough to have a good idea ,you then have to construct it . I always wonder why nobody builds flip up shelves or tool holders into the doors to provide a place to put shit on when you're working on the bike between rides.
That's currently in the plan but a little further downstream...
TailSoHard
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1656
Joined
10/18/2014
Location
Beer City, MI, USA
7/28/2016 6:14am
I want this van sooo bad, but it's a little out of my price range... But just in case this thread is giving anyone else some ideas, here's one to consider. Hopefully someone else here will buy it and turn it into the kickass moto-van I know it could be! Cool

http://kalamazoo.craigslist.org/ctd/5700829213.html
Markee
Posts
3665
Joined
4/15/2013
Location
Suffolk, VA, USA
7/28/2016 6:25am
TailSoHard wrote:
I want this van sooo bad, but it's a little out of my price range... But just in case this thread is giving anyone else some...
I want this van sooo bad, but it's a little out of my price range... But just in case this thread is giving anyone else some ideas, here's one to consider. Hopefully someone else here will buy it and turn it into the kickass moto-van I know it could be! Cool

http://kalamazoo.craigslist.org/ctd/5700829213.html
Sell some shit and get it man. You never promised tomorrow.

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