Rehabbing the Rescue Van

[ThumperX]

The shower pump pliugs inyo the cigarette lighter which is awesome!In order to keep my bed dry I rigged up a shower curtain but I think sometime in the future I'll get rid of the rod and sew in some magnets.
Shower works great and with 20-30 gallons of water storage I'll be in good shape.

Here's a nice picture from my trip.

 

[Eric B]

Good stuff G!

 

[ThumperX]

FINALLY!!!! I got the parts all the way from Poland to fix the windshield surround. The scuttle looks like a straight forward install but removing the old rotten part requires a little more strength than I have.
If there is an unemployed barfer who wants to help tackle this project please let me know and we can talk cash

Also, the van is getting a new black shepherd puppy!!!

 

[ThumperX]

Choosing the worst weather in California history we have begun the process

With a lot (and I mean a lot) of help from an un-named barfer we removed the windshield and began operation "rust."

Believe it or not it looks worse than it is.

Windshield removed

Extent of rusted scuttle:

Closeup of rust damage to scuttle:

 

[ThumperX]

We're using structural pour foam in order to shape the windshield surround. This will be overlaid with fiberglass for strength.
Once our new laser welder is up and running metal will be added to the roof area before paint.

Fitting the new scuttle:

 

[Abacinator]

https://www.youtube.com/watch?v=yIm7nXG1cSw
[youtube]yIm7nXG1cSw[/youtube]

 

[ThumperX]

Yeah Holy rusted Metal all right!!
Most of what's rusted has no structural value, Mercedes lays a skin over the structure and that hails miserably once water gets in.

Considering this van was pretty much sold for scrap I can forgive its rust lumps.

Replacing that scuttle will allow the windshield to actually stay in place. The foam will keep any water from migrating under the upper seal and back through the pillars. I'm considering taking a mold off a friends van and making up a set of carbon fiber pillar covers for the outside.

 

[Escape pod]

vanlife Pepper … that is a endearing name.

 

[ThumperX]

Considering that I’m now as old as AFM199 when we started teasing him about being old it really doesn’t matter if this little van completely melts in the course of my remaining years. It’s a fantastic get away vehicle for just me, my dog, and my bike.

 

[ThumperX]

For the first time in probably a decade Pepper is 100% waterproof!

We installed the Harbor Freight mod before the rain really hit

 

[budman]

100%...! and yes what a year to take this on!

 

[GAJ]

It’s a fantastic get away vehicle for just me, my dog, and my bike.

What is your complete $$ outlay putting no value on your time?

You must get a lot of satisfaction out of it, especially when sitting around the campfire at another destination.

 

[ThumperX]

As of today I’m about $4k in. When it’s all over I’ll be around $7k
That’s with ain’t and a reasonable comfortable interior.

 

[GAJ]

As of today I’m about $4k in. When it’s all over I’ll be around $7k
That’s with ain’t and a reasonable comfortable interior.

I paid more than $4k for an e'bicycle a few months back!

Great ROI even when your build is done.

Congrats.

 

[SFMCjohn]

With a lot (and I mean a lot) of help from an un-named barfer …

UN-named BARFer is the best!


fun seeing all the progress and the wonderful van-life sunset pics …

 

[Kurosaki]

https://www.youtube.com/watch?v=yIm7nXG1cSw
[youtube]yIm7nXG1cSw[/youtube]

I don't care what anyone says, Batman Forever is a personal favorite of mine. I would call it a guilty pleasure but I can't because I don't feel guilty at all.

 

[N4teTheGreat]

UN-named BARFer is the best!

The work quality is definitely a reflection of my experience, or lack thereof in doing anything like this so, if you see Pepper out and about, don't look too close

For example Fiberglass "work" from today. Covering the foam filled holes and shoring up the missing metal where the window gets glued in. Probably gonna need a lot of sanding once it has cured

 

[byke]

What a great thread. Go Nate!

 

[ThumperX]

Nathan is the un-named barfer!!
I wish I didn’t have so much work I have not been very much of a part of this project

 

[ThumperX]

N4tetheGreat

Pepper is road worthy. I managed to crack the upper right corner of the windshield but chose to install it anyway. The installer said the fit was better than a lot of new cars.

Nathan is Pepper's hero for sure.