Our client for this project requested an Adventure Van for some multi-day camping trips with family and friends.
The first phase of this project was some initial discovery – to determine the features and functionality it would need, as well as a rough sense of overarching look-and-feel.
We created a survey with some questions and visual thought-starters for our client, asking about intended outdoor activities/gear, cooking and plumbing requirements, sleeping needs, and aesthetic preferences. Based on these answers and early conversations with the client, we started to design layouts. As for the base vehicle, we agreed upon a 4x4 Mercedes-Benz Sprinter van, for a heavy-duty and utterly reliable foundation for his Adventure Van conversion.
Our design would include...
Our design would include: sleeping arrangements for at least four, an in-van table, a small kitchen with camp stove and electric cooler/fridge, a generator, outlets and USB ports, auxiliary interior and exterior lighting, a high-caliber audio system, some safety essentials like fire extinguishers and first aid, and cargo/storage solutions for various camping and outdoor gear.
In addition to a queen-size mattress...
In addition to a queen-size mattress in the rear of the van, we explored options for forward-facing seating closer to the front of the van that could convert to additional bedding. This bench seat has three-point-harness seatbelts that can accommodate child seats, allowing our client’s family to sit close together while on the road, then the bench seat converts to the kids’ bed at night. We’d also include a folding table here for the family to sit at in the van.
In addition to a queen-size mattress...
In addition to a queen-size mattress in the rear of the van, we explored options for forward-facing seating closer to the front of the van that could convert to additional bedding. This bench seat has three-point-harness seatbelts that can accommodate child seats, allowing our client’s family to sit close together while on the road, then the bench seat converts to the kids’ bed at night. We’d also include a folding table here for the family to sit at in the van.
For the van’s kitchen...
For the van’s kitchen, our client’s cooking would primarily be at camp, outdoors, so we designed a custom pull-out camp kitchen that would slide out from under the rear bed, accessible at the rear of the van. We reached out to a company in Australia, called Drifta, who fabricate high-quality trailer and camp-kitchen products. They worked closely with us to build an awesome pull-out unit, specific to our dimensions and the precise camp stove and electric cooler we wanted to use with it.
For the van’s kitchen...
For the van’s kitchen, our client’s cooking would primarily be at camp, outdoors, so we designed a custom pull-out camp kitchen that would slide out from under the rear bed, accessible at the rear of the van. We reached out to a company in Australia, called Drifta, who fabricate high-quality trailer and camp-kitchen products. They worked closely with us to build an awesome pull-out unit, specific to our dimensions and the precise camp stove and electric cooler we wanted to use with it.
In addition to the pull-out kitchen’s access...
In addition to the pull-out kitchen’s access from the rear doors, we wanted to provide interior access to the cooler from under the rear bed. We designed an additional interior appliance console as well, which would house a GoalZero Yeti 3000 generator, an electric kettle, a spigoted water jug, and a cutting board. This would allow optimal access to the van’s kitchen and electrical gear in virtually any scenario, whether on the road, at camp, or in the van for the night.
...our client also asked for an outdoor sleeping option...
On the exterior, our client also asked for an outdoor sleeping option, off the ground, so we researched roomy roof tents in a variety of styles. We selected an extra large hard-shell pop-up tent, with a mattress made of high density foam (similar in feel to a memory foam, but specifically intended for outdoor use as it resists moisture and mold).
...our client also asked for an outdoor sleeping option...
On the exterior, our client also asked for an outdoor sleeping option, off the ground, so we researched roomy roof tents in a variety of styles. We selected an extra large hard-shell pop-up tent, with a mattress made of high density foam (similar in feel to a memory foam, but specifically intended for outdoor use as it resists moisture and mold).
...some awnings and outdoor “rooms”...
Our client also requested some awnings and outdoor “rooms”. We researched many options and our client selected a combination of two side awnings with optional three-wall enclosures, as well as a 270-degree bat-wing-style awning at the rear that would provide shade over the back cooking area.
Once these preliminary considerations and a rough floor plan were approved by the client, we ordered the van, and started prepping for the actual work to begin.
...2019 4x4 3500XD dually Mercedes-Benz Sprinter...
The van was a 2019 4x4 3500XD dually Mercedes-Benz Sprinter high-roof cargo van in the 170” wheelbase extended length.
We took additional measurements...
We took additional measurements and some rough 3D scans to fine-tune our initial design, so we could develop more precisely-modeled CAD files for CNC fabrication.
We took additional measurements...
We took additional measurements and some rough 3D scans to fine-tune our initial design, so we could develop more precisely-modeled CAD files for CNC fabrication.
Then we made the first cuts...
Then we made the first cuts of the rear doors and side panels to create openings for windows.
...this opened up the feel of the interior...
Right away, this opened up the feel of the interior, and further defined our framework.
...this opened up the feel of the interior...
Right away, this opened up the feel of the interior, and further defined our framework.
The side and rear windows...
The side and rear windows and the bump-out “flare” windows were installed and fitted. The bump-outs as delivered were in a base gel-coat finish, so we then sent those to one of our trusted partners for painting in a matching finish.
Early on in our project’s overall timeline...
Early on in our project’s overall timeline, we had been ordering and procuring many parts we would need. Shown here was our initial rough placement of the roof rack, roof tent, awnings and enclosures.
Early on in our project’s overall timeline...
Early on in our project’s overall timeline, we had been ordering and procuring many parts we would need. Shown here was our initial rough placement of the roof rack, roof tent, awnings and enclosures.
With the roof rack’s arrival...
With the roof rack’s arrival, we could then cut our openings for the skylight vents (Dometic Fan-Tastic vents, one front and one rear) and finesse the roof and exterior installation work.
With the roof rack’s arrival...
With the roof rack’s arrival, we could then cut our openings for the skylight vents (Dometic Fan-Tastic vents, one front and one rear) and finesse the roof and exterior installation work.
We had custom ordered the roof rack...
We had custom ordered the roof rack, roof decks, and ladders to work best for our specifications. Then the roof and side exterior camping gear were assembled and put together exclusively with 316 Stainless Steel hardware and properly-rated thread adhesives and locking systems so fasteners would not corrode or loosen.
...a couple of the roof deck panels...
Shown here are a couple of the roof deck panels at the front of the van, while we were in the process of installing them onto the roof rack. All of the custom-fabricated metal parts were powder-coated prior to installation, and sealants were all marine-grade and UV-resistant.
At the front of the roof rack...
At the front of the roof rack, we mounted a series of VisionX auxiliary lights. The wire connections for the lighting were all passed through the roof sheet metal with compression grommets and Deutsch waterproof electric connectors.
At the front of the roof rack...
At the front of the roof rack, we mounted a series of VisionX auxiliary lights. The wire connections for the lighting were all passed through the roof sheet metal with compression grommets and Deutsch waterproof electric connectors.
On the front bumper of the van...
On the front bumper of the van, we mounted a rugged off-road bumper with a WARN winch and two additional VisionX LED lights.
On the front bumper of the van...
On the front bumper of the van, we mounted a rugged off-road bumper with a WARN winch and two additional VisionX LED lights.
We also made some upgrades...
We also made some upgrades and modifications under the hood. Visible here, in red, are Anderson Plugs. The top portion is the power source. When the winch is not in use, you must have it off power or you risk discharging the battery. Additionally, a set of 25-ft, 20-gauge jumper cables are supplied in the van, which can plug into the top receptacle if a jump start is needed – makes easy work of it.
We also made some upgrades...
We also made some upgrades and modifications under the hood. Visible here, in red, are Anderson Plugs. The top portion is the power source. When the winch is not in use, you must have it off power or you risk discharging the battery. Additionally, a set of 25-ft, 20-gauge jumper cables are supplied in the van, which can plug into the top receptacle if a jump start is needed – makes easy work of it.
We also installed an ARB Air Compressor...
We also installed an ARB Air Compressor in the engine bay where there was an available space for it, along with a toggle on-off switch for ease of use.
One other nifty feature on the exterior...
One other nifty feature on the exterior of the van is the Sure Eject plug by Blue Sea Systems, which tops off both the main battery and the auxiliary Goal Zero generator. It automatically unplugs itself when the engine is started.
While the exterior and engine bay were being optimized for better performance, ease of maintenance, and increased off-road capabilities, we also began working on the van’s interior.
Inside the van, we started building...
Inside the van, we started building the interior living space for our client and his family.
We refined our original floor plan...
We refined our original floor plan files per the exact specs and precise dimensions of our van model with our window and skylight cut-outs, and developed more detailed CAD files, in both 2D and 3D.
We fleshed out the CAD-model...
We fleshed out the CAD-model for what we’d be milling on our in-house CNC machine, and incorporated tolerances for insulation and wiring that would be added later on.
We fleshed out the CAD-model...
We fleshed out the CAD-model for what we’d be milling on our in-house CNC machine, and incorporated tolerances for insulation and wiring that would be added later on.
We fleshed out the CAD-model...
We fleshed out the CAD-model for what we’d be milling on our in-house CNC machine, and incorporated tolerances for insulation and wiring that would be added later on.
We also ordered several wood samples...
We also ordered several wood samples that felt aligned with the rustic aesthetic our client was seeking. We reviewed options with our client, for the walls and for the flooring, and then placed a larger order for raw material in our selected wood combo.
At the rear of the van...
At the rear of the van, we installed a draw-bridge style platform bed frame, and mounted an auxiliary HVAC unit to the underside of the frame, for better climate control in the camper’s living/sleeping areas.
At the rear of the van...
At the rear of the van, we installed a draw-bridge style platform bed frame, and mounted an auxiliary HVAC unit to the underside of the frame, for better climate control in the camper’s living/sleeping areas.
Also at the rear of the van...
Also at the rear of the van, we installed a HiFonics Bluetooth audio bar, to be housed within the custom wood paneling. This faces outward for use when the campsite is deployed, and it’s powered by the Goal Zero generator, which we incorporated into the van’s auxiliary gear to prevent main battery discharge. The Goal Zero allowed us to add increased functionality to the Adventure Van without compromising the main battery.
Also at the rear of the van...
Also at the rear of the van, we installed a HiFonics Bluetooth audio bar, to be housed within the custom wood paneling. This faces outward for use when the campsite is deployed, and it’s powered by the Goal Zero generator, which we incorporated into the van’s auxiliary gear to prevent main battery discharge. The Goal Zero allowed us to add increased functionality to the Adventure Van without compromising the main battery.
Also at the rear of the van...
Also at the rear of the van, we installed a HiFonics Bluetooth audio bar, to be housed within the custom wood paneling. This faces outward for use when the campsite is deployed, and it’s powered by the Goal Zero generator, which we incorporated into the van’s auxiliary gear to prevent main battery discharge. The Goal Zero allowed us to add increased functionality to the Adventure Van without compromising the main battery.
In the front cab...
In the front cab, we replaced the OEM tweeters with Scan-Speak tweeters. (Often, OEM tweeters are wedged into the triangular intersection where the top corners of the dash meet the windshield, and are aimed at a less-than-ideal angle.) We removed the OEM tweeter housings and replicated their shape and fastening points, in order to match fitment. Then we used a 3D scan of this corner to maximize our use of this space without getting too close to the windshield glass.
In the front cab...
In the front cab, we replaced the OEM tweeters with Scan-Speak tweeters. (Often, OEM tweeters are wedged into the triangular intersection where the top corners of the dash meet the windshield, and are aimed at a less-than-ideal angle.) We removed the OEM tweeter housings and replicated their shape and fastening points, in order to match fitment. Then we used a 3D scan of this corner to maximize our use of this space without getting too close to the windshield glass.
We CAD-modeled a lofted hooded enclosure...
We CAD-modeled a lofted hooded enclosure to house the new tweeter at a more upright and directional angle for better high-frequency sound. We 3D-printed these in-house and finished them to match the rest of the dash, then they were wired into the existing OEM locations and snap-fit firmly in place.
We CAD-modeled a lofted hooded enclosure...
We CAD-modeled a lofted hooded enclosure to house the new tweeter at a more upright and directional angle for better high-frequency sound. We 3D-printed these in-house and finished them to match the rest of the dash, then they were wired into the existing OEM locations and snap-fit firmly in place.
Also in the front cab...
Also in the front cab, we removed the OEM seats (to be replaced with swivel seats we ordered, so they could turn to face the bench seat and fold-down table). Then in the cavities of both seat bases, we fully utilized this space for some additional wiring, fuses, and audio components. In the passenger seat, we installed a subwoofer inside/under the seat (hidden from view when the seat was re-installed), and on the back of each seat we mounted a JL Audio amplifier, in a custom-fabricated wood housing.
This photo shows a closer view...
This photo shows a closer view into the driver-side seat, annotated with some notes from Matt to the client to show what’s what: the HVAC reset/fuse access and breaker, the main fuse panel, the Audiotech Fischer Match mini amp, and the relay bank.
Additionally, in the driver’s seat...
Additionally, in the driver’s seat, we housed the fuses for: the Goal Zero battery charge lead, the trickle charger for the OEM battery under the hood, and the ARB air compressor.
This view shows a clear aperture...
This view shows a clear aperture in the side of the driver’s seat (hidden by the seat’s adjustor handle), with access to the HVAC reset controls. This was cut in by us, as a sight to inspect.
And on the seat’s exterior...
And on the seat’s exterior, these photos show the fuse block’s access panel, and our careful labeling of the fuses housed within.
And on the seat’s exterior...
And on the seat’s exterior, these photos show the fuse block’s access panel, and our careful labeling of the fuses housed within.
With everything neatly contained...
With everything neatly contained inside the seat cavities, the swivel seats were installed.
One more component we added...
One more component we added in the front cab was a multimedia head unit display/control touch screen in the dash.
And overhead, in the headliner...
And overhead, in the headliner, we installed the Premier Products climate control panel and switches for the auxiliary lighting.
And overhead, in the headliner...
And overhead, in the headliner, we installed the Premier Products climate control panel and switches for the auxiliary lighting.
Back to the main living area of the Adventure Van, this next series of images shows more of the interior fabrication.
In the main cabin...
In the main cabin, we started CNC’ing and installing the interior woodwork panels.
...we began fabricating the upper cabinetry.
Once the primary walls were in place around the windows, we began fabricating the upper cabinetry.
...panels being milled in-house...
Shown here are a few photos of panels being milled in-house on our CNC router.
...panels being milled in-house...
Shown here are a few photos of panels being milled in-house on our CNC router.
...panels being milled in-house...
Shown here are a few photos of panels being milled in-house on our CNC router.
These upper components...
These upper components were a combination of storage cabinets and netted cubbies, designed to provide the best mix of storage solutions, head room, and ease of motion within the interior. Aesthetically, this also offered a more open feeling to the space and added visual interest.
These upper components...
These upper components were a combination of storage cabinets and netted cubbies, designed to provide the best mix of storage solutions, head room, and ease of motion within the interior. Aesthetically, this also offered a more open feeling to the space and added visual interest.
Another key feature in our build...
Another key feature in our build was a two-way sliding mechanism that could lock and release in two directions for the Drifta pull-out kitchen unit. We wanted to design a way for the kitchen to pull out completely from the rear of the van, and also be able to partly pull open inward, to allow enough clearance to access and open one of the cooler lids from inside the van.
Another key feature in our build...
Another key feature in our build was a two-way sliding mechanism that could lock and release in two directions for the Drifta pull-out kitchen unit. We wanted to design a way for the kitchen to pull out completely from the rear of the van, and also be able to partly pull open inward, to allow enough clearance to access and open one of the cooler lids from inside the van.
Another key feature in our build...
Another key feature in our build was a two-way sliding mechanism that could lock and release in two directions for the Drifta pull-out kitchen unit. We wanted to design a way for the kitchen to pull out completely from the rear of the van, and also be able to partly pull open inward, to allow enough clearance to access and open one of the cooler lids from inside the van.
To achieve this two-way sliding system...
To achieve this two-way sliding system, we incorporated two sets of 500-lb drawer slides, and fabricated clever CNC’ed plastic guides. These are locking on both ends, for great ease of use.
To achieve this two-way sliding system...
To achieve this two-way sliding system, we incorporated two sets of 500-lb drawer slides, and fabricated clever CNC’ed plastic guides. These are locking on both ends, for great ease of use.
To achieve this two-way sliding system...
To achieve this two-way sliding system, we incorporated two sets of 500-lb drawer slides, and fabricated clever CNC’ed plastic guides. These are locking on both ends, for great ease of use.
Next, the ceiling went in...
Next, the ceiling went in. These panels would also house overhead LED lights running the length of the van.
Next, the ceiling went in...
Next, the ceiling went in. These panels would also house overhead LED lights running the length of the van.
The lower portion side walls...
The lower portion side walls were next to go in, followed by CAD-design and CNC fabrication of the steps to the bed.
The lower portion side walls...
The lower portion side walls were next to go in, followed by CAD-design and CNC fabrication of the steps to the bed.
We then designed an interior appliance console tower...
We then designed an interior appliance console tower with compartments for the Goal Zero generator, an electric kettle, and a water jug, as well as a netted cubby for tablets/phones while they’re charging, and a cutting board surface on top. And next to this unit, where the bench seat folds down, we designed a storage trunk for bedding (where one can also sit when accessing the cooler from under the bed).
We then designed an interior appliance console tower...
We then designed an interior appliance console tower with compartments for the Goal Zero generator, an electric kettle, and a water jug, as well as a netted cubby for tablets/phones while they’re charging, and a cutting board surface on top. And next to this unit, where the bench seat folds down, we designed a storage trunk for bedding (where one can also sit when accessing the cooler from under the bed).
Between the bench seat and the front cab...
Between the bench seat and the front cab, the next item we designed was a folding table, at a height that would be comfortable from both the bench seat and the front swivel seats when swiveled around. And on either side of the table, on the side wall, we added electrical outlets and USB ports. (More photos to follow, later in our build, of the finished table with its folding table leaf.)
Between the bench seat and the front cab...
Between the bench seat and the front cab, the next item we designed was a folding table, at a height that would be comfortable from both the bench seat and the front swivel seats when swiveled around. And on either side of the table, on the side wall, we added electrical outlets and USB ports. (More photos to follow, later in our build, of the finished table with its folding table leaf.)
Another step worth mentioning...
Another step worth mentioning is some finely-detailed handiwork done “mudding” the panels, especially at junction points, to finely mate the joints. Once this was complete, and all our paneling was in place, it may seem surprising that our next step would be...
Another step worth mentioning...
Another step worth mentioning is some finely-detailed handiwork done “mudding” the panels, especially at junction points, to finely mate the joints. Once this was complete, and all our paneling was in place, it may seem surprising that our next step would be...
...we needed the panels out of the van...
to take everything out... This was for two reasons – we needed the panels out of the van for our finishing process, and we also needed to access the areas behind the panels, at it was now time to install insulation and finalize some wiring that would live behind these panels.
With the paneling temporarily removed...
With the paneling temporarily removed, the insulation went in, and more interior wiring was finalized, neatly bundled and securely fastened.
The windows were finished as well.
The windows were finished as well.
The ceiling panels were upholstered...
The ceiling panels were upholstered in a two-tone arrangement with a highly-textured fabric, and re-installed, along with the LED ceiling lights.
The ceiling panels were upholstered...
The ceiling panels were upholstered in a two-tone arrangement with a highly-textured fabric, and re-installed, along with the LED ceiling lights.
And the floor panels were carefully measured...
And the floor panels were carefully measured, laid out, and installed.
In the rear of the van...
In the rear of the van, under the bed, an access panel opens to a rear fuse panel, exclusively for the circuits powered by the Goal Zero. Also visible in these photos are under-bed lights and L-Track we installed in the cargo bay.
In the rear of the van...
In the rear of the van, under the bed, an access panel opens to a rear fuse panel, exclusively for the circuits powered by the Goal Zero. Also visible in these photos are under-bed lights and L-Track we installed in the cargo bay.
In the rear of the van...
In the rear of the van, under the bed, an access panel opens to a rear fuse panel, exclusively for the circuits powered by the Goal Zero. Also visible in these photos are under-bed lights and L-Track we installed in the cargo bay.
...the finished wood paneling went back in...
Then all of the finished wood paneling went back in, plus the mattress that we had custom-made.
With the Adventure Van nearly complete, our final steps were some fine-tuning and last details.
We took it on the road for a test drive.
We took it on the road for a test drive.
And we deployed the roof tent...
And we deployed the roof tent and all of the awnings and enclosures.
...we added some final items...
Back at the shop, we added some final items like bedding, and some camping supplies like propane for the camp stove.
...we added some final items...
Back at the shop, we added some final items like bedding, and some camping supplies like propane for the camp stove.
Final safety features were added...
Final safety features were added as well: fire extinguishers, a first aid kit, a reaching tool for safe/easy control of the rear audio controls, and warning labels within driver’s view for the van’s clearance height.
Final safety features were added...
Final safety features were added as well: fire extinguishers, a first aid kit, a reaching tool for safe/easy control of the rear audio controls, and warning labels within driver’s view for the van’s clearance height.
Final safety features were added...
Final safety features were added as well: fire extinguishers, a first aid kit, a reaching tool for safe/easy control of the rear audio controls, and warning labels within driver’s view for the van’s clearance height.
Following are some additional photos...
Following are some additional photos of the finished van.
...photos from the rear bed...
A couple photos from the rear bed offer another perspective.
...photos from the rear bed...
A couple photos from the rear bed offer another perspective.
Our paint is a highly durable...
Our paint is a highly durable and resilient truck-bed coating, color-keyed to match our wood color.
Our paint is a highly durable...
Our paint is a highly durable and resilient truck-bed coating, color-keyed to match our wood color.
Secondary AC vents were incorporated...
Secondary AC vents were incorporated into the foot-of-the-bed fascia panel. And we installed utilitarian recessed drawer pulls for the cooler pull-out and bench seat storage cubby.
Secondary AC vents were incorporated...
Secondary AC vents were incorporated into the foot-of-the-bed fascia panel. And we installed utilitarian recessed drawer pulls for the cooler pull-out and bench seat storage cubby.
We CNC’ed the folding table...
We CNC’ed the folding table in solid maple, featuring yacht-style table hinges and mortised/hidden magnets for the table leaf. Then for fold-down stowing, we employed clever swing-out hinges with integral ball catches.
We CNC’ed the folding table...
We CNC’ed the folding table in solid maple, featuring yacht-style table hinges and mortised/hidden magnets for the table leaf. Then for fold-down stowing, we employed clever swing-out hinges with integral ball catches.
Shown here are a few more photos...
Shown here are a few more photos of the Adventure Van out in the great outdoors.
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