2013 Chevy Express 3500 Cutaway Expo Build

[HiLife]

I will be following this cool build. Always wanted to do something like this!
Cool that you are doing it!

 

[MStudt]

I will be following this cool build. Always wanted to do something like this!
Cool that you are doing it!

I need to get some new picture posted since I've been slacking on it.

Mike

 

[MStudt]

Here's an update since I've been slacking at it.

I have a lot going on right now, and I'll try my best to recap everything. The ceiling is just about finished, and I only need 2 more pieces of blue pine to go up. I'm going to hold off on that until I get all of my wiring complete, and make sure that I'm 100% leak-free on the roof. I installed a Step-Above fold-down step that makes getting in and out a breeze. This has adjustable legs for uneven ground and folds up into the door jam when stowed away. We were having issues with our paint of choice not wanting to be durable enough. So we design a sticker and cover the front bulkhead and rear doors with them. These are very durable and easy enough to remove should some get damaged. I also received my Fiamma F45S awning today and was able to mount it to the roof rack mounts that I design with ease.

 

[momo.75]

Man, that is looking awesome!

 

[MStudt]

I've been slacking about posting pictures of the progress, and trips. For the most part the van is complete, and I'm pretty happy with how everything turned out. I still need to build bumpers, and do a little more electrical work.

 

[momo.75]

I've been slacking about posting pictures of the progress, and trips. For the most part the van is complete, and I'm pretty happy with how everything turned out. I still need to build bumpers, and do a little more electrical work.

That is awesome!

 

[MStudt]

A couple of weeks ago I started on the rear bumper and tire carrier. I'm reducing the overall depth of the rear step by 5" and shortening it on each side by roughly 12". First I removed the old flaking thread plate, spreader and got everything prepped for the new crossmember.

 

[MStudt]

Next up was welding in a new 2" x 3" x .120 crossmember with a 2" receiver hitch. The receiver hitch will only be used for hauling our bike and never used for towing anything. So I wasn't overly concerned about the size of the material. I made some side plate reinforcements from 7 ga CRS that ran the length of the dog legs and wrapped around the rear onto the new crossmember. The top plate is a galvanized perforated stair thread that uses carriage bolts run though connector plates.

 

[MStudt]

Over the weekend I was able to start building the swingout tire carrier, and almost finished it. The carrier hinge is a 4xInnovations, and all the tubing for the swingout is 1-3/4" x .120 DOM. I also purchase the tire mounting plate from Ruff Stuff, and the a compression latch from SouthCo going on. Building this also gave me an excuse to use the JD2 vertical bender again.

I still need to design and build a mount for a AT Overland Equipment jerry can holder, and design a mount for a Zarges aluminum case. The aluminum box will serve as a small storage area, and a small work surface when opened.

 

[rdruss]

Love to watch people who have the skills and tools to fabricate, they can bring their ideas to life! Thank you.

 

[MStudt]

I'm jumping backwards a little since I don't think I ever posted the electrical setup in the rear of the van. We have two 100w solar panels on the roof with a 200Ah hybrid gel battery running everything. We're using a Victron MPPT 75/15 controller, Victron shunt, and Victron Blue Smart Charger. Several Blue Sea breakers, Blue Sea blocks, Blue Sea fuses, Blue Sea fuse panel, and Blue Sea Disconnect. We also have a Victron 1000w power inverter, and will have a Victron converter once we're hooked up to the alternator.

 

[MStudt]

If you know you know. About to get comfy and warm.

 

[MStudt]

I've been trying to wrap some things up before departing for our road trip on 12/23 when we head into No-Cal for a week. That means I should be dumping a lot of updates over the next couple days.

First update is small, but pretty significant. I recently purchased some insulated window and fan covers from Tourig. These are a very nice window cover that's super easy to install and use with them being held up by a few magnets. I also have them working on some custom covers for our back windows since no one seems to make anything for those.

 

[MStudt]

This morning I was able to finish up the rear bumper, and just in time for our upcoming trip tomorrow. The aluminum box was a bit of a last minute idea that'll double as a work center. I'll be able to store some item in this, and have a flat work space if needed.