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Old 06-05-2015, 11:40 PM   #1
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Default Building Annie: A Campervan Conversion

Our Annie the Van came home on 21 May., looking thus:
Annie is home! by stan, on Flickr

So, it's now time to start documenting the build. The documenting pictures will be viewable at
https://www.flickr.com/photos/skagit...57653213165316
There will likely be some photos there that I don't post here.

This arrival was followed by a couple of days of head scratching, then ordering and picking up a bunch of supplies for the upcoming project.

The layout will look something like this rough sketch:


The first project is to install a Maxxair fan.

We started by making a template for the opening, locating where the hole will go from the inside, drilling a template center-hole through the roof, and using that to position the template on the outside. The Maxxair's frame corners have about a .5" radius, so I use a 1""punch.




continued after the pic limit break
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Turning a 2015 Ford Transit into a camper. Her name is Annie.
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Old 06-05-2015, 11:41 PM   #2
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Default installing the Maxxair continued

Next step is taping the outline (inside and out) and punching out the corners.





continued after the pic limit break
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Old 06-05-2015, 11:42 PM   #3
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Using a dull scalpel, I cut along the hole outline


Thus creating a place for rain to go if we ever want to turn the sleeping bed into a garden bed


After a bit of smoothing rough cutout edges, and ant-rust painting the raw edges, the frame fits


Cleanup and beer break


continued
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Old 06-05-2015, 11:44 PM   #4
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The frame is screwed through the roof into plywood strips. The strips are being held to the roof by VHB tape, so I gave the tape a good squeeze to make sure there is good roof contact. The screws are stainless, so there should be no electrolysis issues screwing through the roof. There are strips on the other 2 sides as well, but no pics of that.


The frame is screwed in over several layers of caulking strip, squashed out excess is trimmed off, and we cover the thing in vanilla icing (actually a copious amount of lap sealant). Don't hire me if you want a neat job squirting sealant (or cake icing).


Finally, mounted the fan in the frame


Closed the fan, and we're done.
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Old 06-05-2015, 11:45 PM   #5
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Default finished fan



Next steps were going to be insulating the floor and walls, installing the solar,installing the propane tank, then insulating the roof.
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Old 06-05-2015, 11:46 PM   #6
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Default Next steps...starting the floor

But, the solar, some of the insulation, and propane equipment hadn't yet arrived, so I started some interior work

I removed the wall panels & started floor construction.
The floor will consist of 1.5" thick joists glued to the Transit's floor ribs, rigid foam insulation glued between the joists, a Reflectex blanket, then .5" plywood panels screwed into the joists. There will be PEX lines running through, possibly a gray water line as well, one propane line, and some wiring in electric conduit.

I will cut or notch the joists once I have line locations settled.

The joists are made from 1" rips of a 3/4" ply sheet. Two ripped strips are glued together.


Starting to glue in the strips. I'm using silicon to keep the joint flexible. I have a silly theory that the impedance mismatch between the joists and the metal floor will aid in reducing road noise coupled to & through the plywood floor. The flexibilty of the glue should aid here (if I'm not just being silly.)


Children are starving just so I can hold down the joists while the glue sets up.

It'll be dry for the next few days and the panels and tank have arrived. Tomorrow, I'll finish the joists, then start looking at the solar.

Now it's tomorrow, and the floor joists are in.


I'll be adding some additional support joists in the floor valley around the perimeter
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Old 06-06-2015, 01:32 AM   #7
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Thank you for these pictures. This definitely will be a help and gives me ideas for when I go for a Transit upfit.
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Old 06-06-2015, 06:53 AM   #8
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I love your attention to detail. Looks great. Is the reason for the subfloor just to run propane, fresh and grey lines?
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Old 06-06-2015, 12:03 PM   #9
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Radius edges, painting bare metal after the cutout - nice work! That's an advantage of DIY. You get to take care of the details.

I really like your floor joist idea. That will make it easier to route plumbing & electrical etc. to either side of the coach and also keep it all inside the van.
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Old 06-06-2015, 12:37 PM   #10
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Quote:
Originally Posted by Jostalli View Post
I love your attention to detail. Looks great. Is the reason for the subfloor just to run propane, fresh and grey lines?
Thanks all!
Another major reason is to provide non-load bearing space for the rigid foam insulation and Reflectex that will go in between the joists.
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