The starting point of the interior conversion:
The 4x4 Conversion was engineered and completed by QUIGLEY (Quigley Motor Company, Inc., 100 Sunset Drive, Manchester, PA 17345, US (717) 266-5631).
So, with the 4x4 conversion already done, we started with this 2008 FORD E350, Heavy Duty, Extended Van, with a TRITON 6.8L V10 Engine (Gasoline).
Installation of Front Bumper Guard and 2" Front Receiver
Remove Seats and All Interior Trim
All floor perforations, from previous seat and seat belt installations, were treated with rust reformer, primer, and paint....from top and bottom.... prior to filling the holes with a silicone plug and silicone adhesive. All penetrations were sealed from below as well, with primer, bed-liner (Entire bottom was treated), and several coats of paint.
Insulate All Exterior Walls With Rattle-Can Foam.
Exterior walls are double steel. After drilling holes throughout the exterior perimeter, foam was shot into the cavities in 2" lifts. (Foam used: Great Stuff, Source: Home Depot) Each lift was given 24 hrs or more to fully expand and cure, to reduce chances of "bulging" in the exterior sheet metal. All roof braces were insulated as well, between the brace and the roof metal.
The vent line in the picture below is the vent line for the fresh water tank. The line is run high, and then down to the vent, to prevent exterior water from entering the tank through the vent (Rain water, snow, car wash spray, condensation, etc).
The entire floor was covered with 3/4" mold resistant closed cell foam. The low spots, between the ribs on the floor, were filled with rattle-can expansive foam, to fill the gap and to also act as a mild adhesive to keep the foam in place until cabinets were installed.
The ceiling structural ribs were fully filled with expansive closed cell foam, and the ceiling was treated in a similar fashion as the floor. 3/4" closed cell foam panels were glued to the ceiling. Between the closed cell foam and the finished ceiling panel, another layer of insulation is added later in the process: 2" of shredded blue jean batts (post production material, made from scraps in the production of blue jeans).
One of the ceiling structural ribs had to be removed and re-installed 8" forward, to accommodate the ceiling fan.
The ceiling fan is: MaxxFan Deluxe Roof Vent w/ 12V Fan and Thermostat - Manual Lift - 10 Speed - White ($220.00)
Before the original headliner was re-installed (with a lot of additional insulation installed prior), the center section of the headliner was cut out (the section that contained the air conditioning ductwork). BTW. The rear HVAc unit containtains rear AC and rear Heating coils. The Ac directs itself to the roof vents. I took that vent, capped it off in the riser column, and introduced two diffusers (Made from lighting can-light trims that I painted), to throw the cold air into the rear sleeping area. The factory HVAC controls has a diverter that sends warm air to the lower diffusers. I re-directed the heated air towards the fresh water tank (33 gallons) to basically use that water as a heat sink. The air flows from the water tank area to the rear and up, between the bed and the rear windows.
The cross section photo below shows the insulation related: Expansive foam + 3/4" ridged closed cell foam, + 2" shredded blue jean insulation,
The passenger side rear window was replaced with an opening window, to help in cross ventilation.
Wood floor and cabinet installation
Further insulation and trim details:
Below, a view of the back of the air compressor and tank, below that the water pump, to the left the 33 gallon water tank, and at the bottom the 200 amp-hr AGM Solar battery.
2"-5" of Expansive foam (R=5) between the inside and outside steel layers of the entire van. Between the inner steel layer and the finished panels another 2"-4" of shredded blue jeans (post production-not post consumer) batts were installed. This provides for excellent acoustic (sound) dampening. The foam provides the air infiltration barrier, and the cotton batts provide the sound dampening combined with another R=10. Total R value varies between R=15 to R=35.
A few shots of the finished product:
After the Baja Trip, a few upgrades were added:
November 2020 Additions: New rear bumper (By Anders Rasker), and stogie elder drawer
Spring of 2021 Interior Remodel
In order to gain a bench for eating at, and a table/extension to the counter, I removed the cabinets under the bed and shortened them. The result was a bench that comfortably seats two. The table, which folds up and becomes part of the bed, is attached to the kitchen countertop with a rail. This allows the table to be moved around:
