Gnarvan AWD Express build.

TeleSteve

Adventurer
Just got home from the vans first 7 day trip. So far everything that is done is working great. I didn't have enough time to plumb the heater hoses back to the heat exchanger so no hot water, but the rest of the plumbing and electrical worked great. We had to be in Tucson this last Friday- Saturday for a family event so we made a trip out of it. We left last Monday after making the final tweaks to the van including filling and testing the water system for the first time. While driving to the Grand Canyon we spent the first night in the Mojave desert before pushing the next day to GCNP. We spent 3 days and 2 nights in the park exploring and taking in the big ditch.
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Even the dog took in the scenery.
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The Webasto heater got some use with the below freezing temps, although the Thermostat doesn't seem to be working, it is either on or off, I will have to look into that more now that I home.
We then made a short drive over to check out Arizona Snowbowl. We had just planned to park somewhere on Forest Service land, but ran into and old friend who invited us to Thanksgiving dinner at the Hart Prairie Preserve. So after dinner we just stayed and camped on the preserve. this place was beautiful right on the North slope of The San Francisco Peaks.
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This shot was taken at night by moonlight with the ski resort in the back ground.
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The next morning after -6 degree F night, but the heater kept us toasty warm.
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The old cabin where we shared Thanksgiving with one old and about 20 new friends. We then spent most of the day skiing at Snowbowl before making the drive down to Tucson.
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We spent the next two nights with family and friends in Tucson before making the 12 hour drive home yesterday in holiday traffic.
Overall it was a great trip and my wife who has been skeptical of this whole van thing is ready to take another trip. I still have a lot of work to do to get it finished but at least it is usable at this point. My next projects will be to get the hot water working and build and plumb the sink cabinet on the side door. I also need to finish the door panels and the rest of the trim pieces.


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Petrolburner

Explorer
Tell me more about how this hot water heater works. There is a heat exchanger that warms your potable water from the hot coolant. So, while driving you run a pump to circulate the water and warm the hot water tank. The hot water tank gradually cools after you shut down. The downside would be no hot water in the morning when you wake up unless you warm up the engine coolant right?
 

TeleSteve

Adventurer
Tell me more about how this hot water heater works. There is a heat exchanger that warms your potable water from the hot coolant. So, while driving you run a pump to circulate the water and warm the hot water tank. The hot water tank gradually cools after you shut down. The downside would be no hot water in the morning when you wake up unless you warm up the engine coolant right?
It is a flat plate heat exchanger that hot engine coolant will pass through when the engine is running and the bypass valve is opened. It circulates using the engine water pump. It will tap off the heater hoses. It will only work while the engine is running. Cold water is pumped through the exchanger to get hot water. No hot water tank so no hot water is stored, although that is possible.
If you added a electric coolant pump you could circulate the engine coolant with the motor off and use residual engine heat. I just plan to use it while the engine is running.
This system is fairly common and there are some commercially available kits.
This is the exchanger I am using:
http://www.amazon.com/B3-12A-Stainl..._UL160_SR160,160_&refRID=1S2BRWWR9M1X8CD46Q0A
To keep the coolant from flowing through it when not needed I will install this bypass valve:
http://www.amazon.com/dp/B000C9DDIA...TF8&colid=33LDYY3JDUY3I&coliid=I3QWQN21X9T5BV
It is vacuum operated so I will use this actuator to operate it from a standard 12v switch:
http://www.amazon.com/Dorman-600-10..._UL160_SR138,160_&refRID=04M2APJBT1DRTX21X6N1
 
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volcomsurfer

Adventurer
Glad to hear the heater worked out. I should be connecting mine here this week. I bought a combo kit that had the water heater to, probably the only difference about our systems. Thanks for the pics, helps me a lot since I'm a visual person.
 

TeleSteve

Adventurer
How did the Bilstein (24-186643) 5100 shocks work out?
I did get the Bilsteins installed before this first trip and there was a slight improvement in handling, and the bump travel was increased considerably. Although when hitting a large bump with the wheels turned just right I now get a tiny bit of tire rub, but not really enough to worry about. A little trimming of plastic should eliminate it.
Overall I am very pleased with the ride and drivability all around, the stock rear springs handle the current weight well. At this point I can't see upgrading to the stiffer 3/4 ton suburban springs, but I haven't added some things yet. The KYB 3/4 ton van shocks may have something to do with the handling, but the van still sits with a slight rake even with the 1" higher lift in front.
 

TeleSteve

Adventurer
Almost forgot to mention that I parked next to this beast at Arizona Snow Bowl
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TeleSteve

Adventurer
Replacing the foam on the used bench seat/bed to get ready for new upholstery. I went with 70 density 3" foam on the seat and 70 density 4" foam over the back platform boards. I built up the edges wrapping the frame with 1/2" 40 density (green in photos).
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While the seats and cushions were at the upholstery shop I worked on the rear door panels and speaker install.
Building the box for the cubby hole and wrapping it with carpet.
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The panels are 1/4" Baltic birch wrapped in vinyl. the door curves where I wanted to mount the speakers so I made tapered trim rings wrapped in gray carpet.

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The upholstery shop knocked the seat and cushions out in two days and I just picked them up this afternoon. I bought OEM neutral wicker to match the front seats. I googled and printed out some pictures of factory express bench seats so they could make the seat look factory. I wanted them more flat with no bolsters so it would be flatter in bed mode.
I am pretty happy with the outcome.
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The rolls you see under the seat are the black out window screens I made by sandwiching Reflectix with black foam lined headliner on one side and automotive carpet on the other. All three layers were glued together with contact cement and then I sewed 1" nylon webbing all around the edges. I will post some more pictures when I can, it's been raining and snowing here lately.
The wood pieces next to them are the start of the rear corner trim pieces.


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