'06 E350 Van Build

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Caligirlnic

Rank IV

Enthusiast II

1,113
Bend, OR, USA
First Name
Nicci
Last Name
miller
New Overland Vehicle Systems Awning!
Just came in, modified the roof rack today to hold it and popped off the old ARB small awning. This one puts a whole lot of coverage around the side and back of the van (not many awnings are big enough) and actually cools down the interior by a noticeable amount
View attachment 161064
One of the poles does come down right next to the stove, but I think we're going to be redoing the kitchen soon so that won't be a big deal (or I can just leave it up). We still get great coverage over the pullout kitchen with just the last burner being outside the coverage of the awning.
View attachment 161063
Closed up it doesn't take up much length of the van, just 7 ft. It is rather thick though
View attachment 161069

Overall we're very happy with the new awning and how it works. Construction seems stout, welded aluminum hinges and it was holding up well to the wind while we were deploying it. Definitely looking forward to testing it out camping soon, but BBQing with neighbors on the 4th of July will have to suffice for it's first test run :)

We also got started on rebuilding and regearing the Dana 60. Just started tearing it down and cleaning it off
View attachment 161070
what is the roof rack you have for the awning?
 

Built By Fluffy

Rank II
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Contributor III

289
California, USA
Member #

13163

what is the roof rack you have for the awning?
Custom built. I used work van ladder rack for the clamps that attach to the rain gutter and welded those to a giant U shape I bent out of 1"x1" square tubing. There are 8 clamps, 2 at the rear and 3 on either side
DSC00250.JPG

It fits around the sides and back of the high top with a slight bend downward just aft of the front doors to contour the rain gutter. It's secure enough for the awning or as a decent hand-hold. Eventually I'd like to replace it with an full aluminum roof rack, but we'll get there when we get there
 

Built By Fluffy

Rank II
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Contributor III

289
California, USA
Member #

13163

Start of the kitchen box, just need to modify my welder to work with a spool gun
DSC00724.JPG

It'll be roughly 36"L x 24"W x 14" tall, in the aluminum box/platform will be one drawer and space for one of our large plastic bins. The top will hold our Iceco fridge, 5 gal water can, solar generator, and coleman stove. The whole thing will bolt to the floor via the seat bracket bolts and one seatbelt bolt (seen above)
 
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Built By Fluffy

Rank II
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Contributor III

289
California, USA
Member #

13163

The window is gone! And I'm updating/fixing the aux tank fuel fill neck.
Wife n I planned on deleting the rear driver side window from the beginning (originally both, but we decided to keep the pass rear window). There was a company out there that used to make aluminum window delete kits but they appear to have disappeared, so what's an amateur welder to do?
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Window "blank" cut from a junkyard work van (has the required curvature) and conveniently the bolt holes for the original window are the same diameter hole I would typically drill if I'm trying to emulate a pinch weld using mig.
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Weld through primer paint and "weld through" seam sealant were used in between the two sheets of metal and securely(?) clamped using a saw horse. Prime note for anyone wanting to emulate, I've discovered the "weld through" seam sealer is for resistance pinch welding ONLY...
I may have earned my callsign "Smokey" all over again today...
DSC00741.JPG DSC00746.JPG
Prepped for paint and final result. It looks nice enough if you don't get up close, but it gets the job done, increases our privacy, and gives us much more surface area for insulation later on.

As for the rear fuel tank, the nice expensive dual filler neck didn't work out. Its a nice product, nothing wrong with it, but considering the location of the tank the length of hose required I haven't been able to fill the rear tank at any gas station. So I fabbed up a hidden rear filler
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Welded and seam sealed in a similar fashion to the door, the donor was an S10 truck. It's angled right down to where the fill hole of the rear gas tank is. There was no other place we could figure out to put the fill cap on the outside without removing the rear air conditioning, and this still keeps the fill cap hidden from view. We figured we don't need access to it unless specifically going on long trips (so it's a convenient enough spot) and it's not too intrusive on our rear storage since I'll be building a drawer system anyway
 
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OverlandRS

Rank III
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OB1

Traveler I

509
Portland, OR, USA
First Name
TJ
Last Name
LoMac
Member #

25937

Nice truck interesting mods! If I need to go bigger than the BroncoSport a full size Econoline 4x4 is what it will be unless I can find a S&S M1078 cheap.
 

Built By Fluffy

Rank II
Member

Contributor III

289
California, USA
Member #

13163

Nice truck interesting mods! If I need to go bigger than the BroncoSport a full size Econoline 4x4 is what it will be unless I can find a S&S M1078 cheap.
Thanks! I really wanted to build an LMTV but the wife said no :(
The van has been great though, all considering having camp set up as soon as parked and still being able to fit in normal parking spaces are major bonuses
 
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OverlandRS

Rank III
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OB1

Traveler I

509
Portland, OR, USA
First Name
TJ
Last Name
LoMac
Member #

25937

I grew up every school break in a 1969 TEC Ford Econolone poptop camper. I remember pulling into camp, and dad would pop the top and set hammocks in place, by the time mom and us kids were back from toilets, all ready for dinner and bed. I remember we had a shore power cord but once Dad and Grandpa installed the dual battery system we never use it. I really think a 4x4 or just lifted van is the ultimate offgrid long term adventure vehicle. Picture Not Ours; but basically identical to our Harvey blue 2WD Econoline.
 

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