Designed for a client who promotes music festivals and public-assembly events, this RV elevates van life to a new level.
Of all our projects, this cheerful camper may hold the record for prompting the most spontaneous smiles and inquiries when anyone enters our shop. It’s truly an eye-catcher. This RV is a 1977 GMC Kingsley Motorhome, meticulously restored, repainted, and customized for our client, a concert promoter with many seasonal events that reveal a deep reverence for community and collective experience. He wanted to commission a custom camper, especially for future summer festival seasons.
Our client specifically wanted...
Our client specifically wanted this particular make and model of RV, in part for its dimensions and size, but even more for its undeniable nostalgic quality. He sent us the photo shown here for a visual reference. So, to begin our research, we joined a club, GMC Motorhomes International (GMCMI) – a dedicated group of GMC owners and enthusiasts – to learn more and to help us source our base vehicle.
At the same time, on a parallel...
At the same time, on a parallel path with our search for the RV we’d purchase to start our build, we got some detailed diagrams and specs (also through the GMCMI club) for the model we were interested in. With these diagrams we could begin designing layouts for our client.
Our next step was to begin...
Our next step was to begin modeling some proposed floor plans in CAD, and presented our client with some options as CAD renderings.
Our next step was to begin...
Our next step was to begin modeling some proposed floor plans in CAD, and presented our client with some options as CAD renderings.
We also rendered our client’s...
We also rendered our client’s requested exterior paint scheme, as well as a couple alternate options in case he was interested in a different look.
We also rendered our client’s...
We also rendered our client’s requested exterior paint scheme, as well as a couple alternate options in case he was interested in a different look.
We also rendered our client’s...
We also rendered our client’s requested exterior paint scheme, as well as a couple alternate options in case he was interested in a different look.
Meanwhile, we sourced a vehicle...
Meanwhile, we sourced a vehicle. We had learned through the GMCMI club about a GMC motorhome service center called Cinnabar Engineering in Michigan. They sell and restore original GMC motorhomes, and we were able to purchase our client’s requested GMC Kingsley model through them.
...we purchased a base vehicle that would work...
Through Cinnabar, we purchased a base vehicle that would work well for this project. With Cinnabar’s vast expertise and experience on GMC motorhomes, we also commissioned them to handle preliminary restoration work.
...had a mostly empty/gutted interior...
The motorhome we purchased had a mostly empty/gutted interior, allowing us to take additional detailed measurements very early on, while the RV was still off-site, so we could continue refining our CAD layout at the same time that Cinnabar was handling restoration work.
...had a mostly empty/gutted interior...
The motorhome we purchased had a mostly empty/gutted interior, allowing us to take additional detailed measurements very early on, while the RV was still off-site, so we could continue refining our CAD layout at the same time that Cinnabar was handling restoration work.
...color selections for the exterior paint...
Here in New York, we confirmed with our client the color selections for the exterior paint, which Cinnabar would be handling in Michigan.
Cinnabar primed and painted...
Cinnabar primed and painted the RV and restored all the glass.
Cinnabar primed and painted...
Cinnabar primed and painted the RV and restored all the glass.
Cinnabar primed and painted...
Cinnabar primed and painted the RV and restored all the glass.
Cinnabar primed and painted...
Cinnabar primed and painted the RV and restored all the glass.
...restored all of the mechanicals...
Cinnabar also restored all of the mechanicals, installed the gray water tank, and supplied for us (loose) many of the other components that we’d be installing once we got the RV back to our shop in NY.
...restored all of the mechanicals...
Cinnabar also restored all of the mechanicals, installed the gray water tank, and supplied for us (loose) many of the other components that we’d be installing once we got the RV back to our shop in NY.
Next, when the RV was delivered to our shop in NY, we began the full custom build.
With this being a large and long-term project...
With this being a large and long-term project, our first step was to stage our work site for it. We placed it on our largest lift in a location where our team would have unfettered access while also being able to safely move other vehicles and projects around it.
...our blank canvas...
Here are a couple photos of the empty interior – our blank canvas – at the start of our work.
...our blank canvas...
Here are a couple photos of the empty interior – our blank canvas – at the start of our work.
We added live tools...
We added live tools like an exterior light switch to power interior lighting and a work table and steps just outside the door. We added blocks to ensure that it was absolutely road-level on the lift. And we set up trickle chargers to protect its battery.
We added live tools...
We added live tools like an exterior light switch to power interior lighting and a work table and steps just outside the door. We added blocks to ensure that it was absolutely road-level on the lift. And we set up trickle chargers to protect its battery.
We added live tools...
We added live tools like an exterior light switch to power interior lighting and a work table and steps just outside the door. We added blocks to ensure that it was absolutely road-level on the lift. And we set up trickle chargers to protect its battery.
Inside the RV...
Inside the RV, we taped off the different “room” portions in conjunction with our client-approved floor plan that we’d been developing while the RV was at Cinnabar.
We posted the full floor plan...
We posted the full floor plan and mechanical details outside the van, and then we started building some of the interior walls.
We posted the full floor plan...
We posted the full floor plan and mechanical details outside the van, and then we started building some of the interior walls.
...the bedroom walls and kitchen...
Among the earliest structural items we installed were the bedroom walls and kitchen area.
...the bedroom walls and kitchen...
Among the earliest structural items we installed were the bedroom walls and kitchen area.
...we installed heating/ducting...
Next, we installed heating/ducting, and a Magnum inverter/charger. We installed the AC/DC panel in an overhead compartment behind the front cab. And taped to the window below that was a comprehensive diagram of all the electrical, propane, and plumbing plans, to keep it at-hand for the team throughout the build process. We also printed a final version of this for our client to have for reference on the road.
Another diagram Matt prepared...
Another diagram Matt prepared showed the detailed media flow chart, as both an FYI for our client, and for our internal team’s reference during the build and wiring.
...various components and mechanicals...
We also worked on various components and mechanicals that are accessed via exterior panels. Shown here is the driver-side panel (with a combination lock on the exterior) for water connection and gravity fill.
...various components and mechanicals...
We also worked on various components and mechanicals that are accessed via exterior panels. Shown here is the driver-side panel (with a combination lock on the exterior) for water connection and gravity fill.
...access panel to the camper’s furnace.
This panel, also on the driver-side exterior, is the access panel to the camper’s furnace.
...access panel to the camper’s furnace.
This panel, also on the driver-side exterior, is the access panel to the camper’s furnace.
...includes refrigerator access and gas...
And this driver-side panel includes refrigerator access and gas plumbing. Also housed within this panel is a CTEK charger for the engine battery.
...includes refrigerator access and gas...
And this driver-side panel includes refrigerator access and gas plumbing. Also housed within this panel is a CTEK charger for the engine battery.
...includes refrigerator access and gas...
And this driver-side panel includes refrigerator access and gas plumbing. Also housed within this panel is a CTEK charger for the engine battery.
...includes refrigerator access and gas...
And this driver-side panel includes refrigerator access and gas plumbing. Also housed within this panel is a CTEK charger for the engine battery.
...we placed the house battery...
Under the hood, in addition to the GMC’s main battery, we placed the house battery here, as well.
...thoroughly tested...
Anything that would ultimately be unseen on the interior (to be accessed via exterior panels only) was fully installed, plumbed, and thoroughly tested before more of the interior structure and furniture came in.
...thoroughly tested...
Anything that would ultimately be unseen on the interior (to be accessed via exterior panels only) was fully installed, plumbed, and thoroughly tested before more of the interior structure and furniture came in.
...thoroughly tested...
Anything that would ultimately be unseen on the interior (to be accessed via exterior panels only) was fully installed, plumbed, and thoroughly tested before more of the interior structure and furniture came in.
Next, more of the plumbing was set in place, particularly for the RV bathroom, and more of the structural framework – additional walls and furniture.
For the bathroom...
For the bathroom, which would be a wet-room environment, we determined the exact footprint for the floor. This would be needed for both the fabrication of the bathroom walls, and for the bathroom interior floor-pan and drain.
...floor-pan and bench...
The next step was fabrication of the floor-pan and bench. The bench would be partly a seat for the shower area, and partly a base for the sink and cabinetry, as shown in the next few photos.
...floor-pan and bench...
The next step was fabrication of the floor-pan and bench. The bench would be partly a seat for the shower area, and partly a base for the sink and cabinetry, as shown in the next few photos.
cabinetry and vanity.
The single-unit floor-pan and bench were installed, as well as the bathroom wall enclosures and the interior cabinetry and vanity.
cabinetry and vanity.
The single-unit floor-pan and bench were installed, as well as the bathroom wall enclosures and the interior cabinetry and vanity.
...a mirror and a medicine cabinet...
The vanity houses a mirror and a medicine cabinet as shown here.
...interior furniture such as the dinette...
At this stage of the overall project, in addition to the bathroom walls and cabinetry, we also installed some other interior furniture such as the dinette and sofa, with storage compartments built in.
...under-seat storage compartments...
The under-seat storage compartments of the sofa house the heating/ducting (closest to the front cab), the Magnum inverter/charger (in the center), and AV/multimedia equipment (in the rear-most compartment near the kitchen unit).
...under-seat storage compartments...
The under-seat storage compartments of the sofa house the heating/ducting (closest to the front cab), the Magnum inverter/charger (in the center), and AV/multimedia equipment (in the rear-most compartment near the kitchen unit).
...a fold-down TV.
Just behind the front cab, in the area by the sofa and dinette, we fabricated a housing for a fold-down TV.
...a fold-down TV.
Just behind the front cab, in the area by the sofa and dinette, we fabricated a housing for a fold-down TV.
...CAD-designed, then CNC’ed...
The TV housing and its hinges and folding mechanisms were first CAD-designed, then CNC’ed. Then hardware was added.
...CAD-designed, then CNC’ed...
The TV housing and its hinges and folding mechanisms were first CAD-designed, then CNC’ed. Then hardware was added.
...CAD-designed, then CNC’ed...
The TV housing and its hinges and folding mechanisms were first CAD-designed, then CNC’ed. Then hardware was added.
...seats were upholstered...
The front cab was carpeted, and the seats were upholstered and installed.
Seat controls, seat-heating...
Seat controls, seat-heating, and USB ports were also installed, as well as a passenger-side chair light.
Seat controls, seat-heating...
Seat controls, seat-heating, and USB ports were also installed, as well as a passenger-side chair light.
Seat controls, seat-heating...
Seat controls, seat-heating, and USB ports were also installed, as well as a passenger-side chair light.
...cameras in the front grill...
On the exterior, we installed cameras in the front grill, under the driver’s and passenger side mirrors, and at rear on the roof.
...cameras in the front grill...
On the exterior, we installed cameras in the front grill, under the driver’s and passenger side mirrors, and at rear on the roof.
...cameras in the front grill...
On the exterior, we installed cameras in the front grill, under the driver’s and passenger side mirrors, and at rear on the roof.
...in-dash display...
And in the cabin cockpit, we installed the in-dash display for the exterior cameras’ feeds.
The next big portion of work was completing the bathroom and kitchen. In addition to the plumbing and installing of faucets and shower, we designed and commissioned custom-made resin sinks, and innovated a lighter-weight and more road-worthy approach for non-ceramic faux tile walls, as shown in this next series of photos.
...bathroom and kitchen sinks...
For the bathroom and kitchen sinks, we worked with a company that specializes in resin. We determined our ideal sink basin shapes and all of the sink and countertop dimensions, then added slight tolerances where needed to account for on-the-road movement and friction. Our client selected a resin color, and the sinks and countertops were custom-made.
...bathroom and kitchen sinks...
For the bathroom and kitchen sinks, we worked with a company that specializes in resin. We determined our ideal sink basin shapes and all of the sink and countertop dimensions, then added slight tolerances where needed to account for on-the-road movement and friction. Our client selected a resin color, and the sinks and countertops were custom-made.
...bathroom and kitchen sinks...
For the bathroom and kitchen sinks, we worked with a company that specializes in resin. We determined our ideal sink basin shapes and all of the sink and countertop dimensions, then added slight tolerances where needed to account for on-the-road movement and friction. Our client selected a resin color, and the sinks and countertops were custom-made.
...final installation...
Upon completion, we tested the fit, with final installation to follow (in conjunction with installing the remaining walls and plumbing). Holes were cut into the resin for the faucets and drains that we’d be adding a little later in our build.
...final installation...
Upon completion, we tested the fit, with final installation to follow (in conjunction with installing the remaining walls and plumbing). Holes were cut into the resin for the faucets and drains that we’d be adding a little later in our build.
...Tile is tricky for an RV...
Meanwhile, for the bathroom walls, our client had asked about partially tiling the walls with subway tile. Tile is tricky for an RV – it’s heavy, and it’s rigid. In an RV, you have to be mindful of weight, and you have to accommodate movement. We also needed to consider our wall dimensions, particularly for one curved wall, as well as substrate adhesion requirements, and waterproofing.
...ceramics and polymers...
To find a viable solution, we researched a wide range of materials – ceramics and polymers – and spoke with various industry experts. At the same time, as a visual reference for our client, we mocked up some options for tile sizes and layouts, and printed these on paper at 100% true scale, to see them in-situ in the RV.
...Corian or Formica...
We netted out with a decision to work with Corian or Formica (different brand names for essentially the same material) – a cool-to-the-touch polymer that is often used for countertops in lieu of stone. We CAD-modeled our plan, and sent renderings and samples to our client for review/approval.
...CAD-designed individual panels...
Corian and Formica are sold in large sheets. We custom CAD-designed individual panels, floor to ceiling, with some material milled out from the backs of the panels to reduce weight, and grout lines milled into the fronts of the panels. We’d then apply grout into these grooves, and affix the faux-tile panels to the existing interior, adding some support substrate where needed.
...CAD-designed individual panels...
Corian and Formica are sold in large sheets. We custom CAD-designed individual panels, floor to ceiling, with some material milled out from the backs of the panels to reduce weight, and grout lines milled into the fronts of the panels. We’d then apply grout into these grooves, and affix the faux-tile panels to the existing interior, adding some support substrate where needed.
...CAD-designed individual panels...
Corian and Formica are sold in large sheets. We custom CAD-designed individual panels, floor to ceiling, with some material milled out from the backs of the panels to reduce weight, and grout lines milled into the fronts of the panels. We’d then apply grout into these grooves, and affix the faux-tile panels to the existing interior, adding some support substrate where needed.
This solved weight...
This solved weight, water and dimensional constraints. And it satisfies the eye in its resemblance to genuine tile.
This solved weight...
This solved weight, water and dimensional constraints. And it satisfies the eye in its resemblance to genuine tile.
We added grout into the panels...
We added grout into the panels. This was a trickier process than usual groutwork, due to the panels not being ceramic tile, so we had to refine our method (with smaller test pieces), and learned as we went, to achieve the desired effect and surface finish.
...CNC’ed a ceiling panel...
We also CNC’ed a ceiling panel in the same material (without grout grooves), for a clean appearance around the skylights and ceiling fan. And, incorporated into the curved wall’s upper edge, where it meets the ceiling panel, we fabricated a “fixture bar” to smoothly integrate the shower controls and wand, and some additional switches and controls.
...CNC’ed a ceiling panel...
We also CNC’ed a ceiling panel in the same material (without grout grooves), for a clean appearance around the skylights and ceiling fan. And, incorporated into the curved wall’s upper edge, where it meets the ceiling panel, we fabricated a “fixture bar” to smoothly integrate the shower controls and wand, and some additional switches and controls.
...added LED lights...
Then we added LED lights around the vanity mirror.
Our final stages consisted of: completing the remaining walls and ceiling (and upholstering for some of those panels), as well as final installation and testing of any remaining plumbing and electronics.
Cabinets and overhead lighting were installed...
Cabinets and overhead lighting were installed. The cabinets have a clean face with no protruding handles or knobs, and use a press-touch action to open and close.
Cabinets and overhead lighting were installed...
Cabinets and overhead lighting were installed. The cabinets have a clean face with no protruding handles or knobs, and use a press-touch action to open and close.
...overhead Dometic climate control panel...
The ceiling and some side-wall portions were then upholstered with gray Alcantara and ultra-suede, and the overhead Dometic climate control panel was installed.
...overhead Dometic climate control panel...
The ceiling and some side-wall portions were then upholstered with gray Alcantara and ultra-suede, and the overhead Dometic climate control panel was installed.
...we added electrical outlets...
In the dinette area, in addition to upholstering this wall area, we added electrical outlets and USB ports.
...we added electrical outlets...
In the dinette area, in addition to upholstering this wall area, we added electrical outlets and USB ports.
...3D-printed a control panel...
At the RV entryway, we also CAD-designed and 3D-printed a control panel for the thermostat and some additional switches. This was then painted in a matching gray.
...TV compartment was finished...
The fold-down TV compartment was finished to match, and tested to ensure everything works properly.
...walls and cabinetry...
The bedroom walls and cabinetry were also installed.
Flooring and plumbing...
Flooring and plumbing were completed. The kitchen faucet and drain were installed and tested.
Flooring and plumbing...
Flooring and plumbing were completed. The kitchen faucet and drain were installed and tested.
...faucet was installed...
The bathroom faucet was installed, and remaining bathroom plumbing was also finished.
We’ll close with some photos of the finished RV, ready for summer music festival fun!
Road-ready!
Road-ready!
Interior view...
Interior view towards living/dining area and front cab.
...kitchen, bathroom, and bedroom.
Interior view towards kitchen, bathroom, and bedroom.
...kitchen, bathroom, and bedroom.
Interior view towards kitchen, bathroom, and bedroom.
...bedroom.
A view into the bedroom.
...bathroom.
A view into the bathroom.
...comfy dinette...
A view of the comfy dinette with its convenient outlets and USB ports.
...custom key chains...
As a finishing touch, we CAD-designed and 3D-printed custom key chains for our client.
...embroidered patches...
And our client got embroidered patches made of the RV, flying in the sky above the clouds!
Happy travels...
Happy travels Zeeek!
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