Another Moto Van Build

Moto810
Posts
815
Joined
1/25/2015
Location
Milton, WV US
10/3/2016 8:49am Edited Date/Time 10/3/2016 8:56am
Yes I started out with a crew van that has the rear bench seat. 4cyl turbo di.

Here is the link to the awning. http://www.rvpartscountry.com/AE9500CaseAwning.html

What you see in the van done took JJ 2 days to do. If you stop into Lake Tahoe on a trip or something like that he can do it quickly. He also can make a fold out bed in this model. Those windows that open came from www.Carid.com

He also insulated the roof and the sides.
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/3/2016 9:42am
Looking great man! Nice work for sure! Your thread has me on the hunt! I am now looking for a van. I live 2.5 hrs from...
Looking great man! Nice work for sure! Your thread has me on the hunt! I am now looking for a van. I live 2.5 hrs from the closest track and want to be fully self contained especially when I am fried on the way home. With a van set up properly I can just pull over and take a nap. I wouldn't mind buying one already set up. If anyone knows of a decent deal hit me up. I am getting rid of my Subaru STI wagon and using that money to go toward a van.
Thanks, man! I'm happy with it so far. I'm probably going to list this for sale when it's finished if you're interested Silly

The Shop

motokawi818
Posts
836
Joined
4/7/2008
Location
Kennewick, WA US
10/4/2016 11:03am
Where's the best place to look for one of those bench seats that pulls out into a bed? RV surplus? Junkyard? Online?
10/4/2016 11:08am
Where's the best place to look for one of those bench seats that pulls out into a bed? RV surplus? Junkyard? Online?
All of those places. The bench/bed was easily the most difficult Item to source when building my Motovan.
CarlinoJoeVideo
Posts
7418
Joined
11/30/2013
Location
Portland/Los Angeles, CA US
Fantasy
2561st
10/4/2016 11:20am
Where's the best place to look for one of those bench seats that pulls out into a bed? RV surplus? Junkyard? Online?
RB Components-
They are expensive but have great folding beds and tons of Other goodies to outfit the vans.
http://www.rbcomponents.com
10/8/2016 9:15pm
love it. I just bought an 07 Express non extended. It's already pretty decently set up though.. I bought it from a moto buddy. I am...
love it. I just bought an 07 Express non extended. It's already pretty decently set up though.. I bought it from a moto buddy. I am contemplating doing something like you have with the extra batteries. I'd like to do a separate stereo for the back with speakers in the doors. I'm no wiring guy though. :-/

build looks awesome. I look forward to continued updates.
john.aron wrote:
I think having house batteries is key. The challenge becomes how to charge them. I went with a battery separator, which will work, but it is...
I think having house batteries is key. The challenge becomes how to charge them. I went with a battery separator, which will work, but it is not cheap to implement. I wish I had gone with a 100W solar panel setup first instead. You can get complete kits on amazon for $180.

I need a mountain bike pretty badly...Hook me up with a Magura and I'll do all your wiring!
Let me know what you need from magura. I can get you a solid deal.

i have a baby coming in December so going all in on my van has changed now. It's already set up decent enough for what I need. I do wish I had a bed setup though for longer trips. It would definitely pay for itself.
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/18/2016 1:30pm
Some good stuff coming later tonight. After tonight things will be real close to finished!
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/18/2016 5:04pm
Progress slowed a little because I ended up trading in the RMZ450 for a '15 YZ450F. Its in great shape with 34 hours, but needed new steering stem bearings (which turned into new triple clamps), some unbreakable levers and a few other goodies.

As she came home


With the new triple clamps and levers


Also did fork and shock seals/oil and lubed up all the suspension bearings. Getting close but still need to check valve clearances and install some tubliss setups. Luckily the air filter fairy visited me today too.


OK...Back to the Motovan



The left side Cabinet is in and looking good! Pressure washer has been bolted down and air gauge and high pressure hose storage setup worked out. The doors are cut but are being painted...maybe those will go in tomorrow night. The right side cabinet is also installed but I'll wait till I finish the top lid before posting...

Also I made a run up to Grant Junction (4.5 hours) a couple weekends ago and fully loaded averaged 18mpg round trip.


1
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/19/2016 9:02pm
Cabinets are finished!! Sorry the photos are not the greatest. It was pretty late when I wrapped it up.



With storage...



Closeup of the left



Closeup of the right



Also got the tubliss setup mounted Cool



Pretty good day. Definitely better than watching the debate...
Grizz
Posts
3109
Joined
7/2/2012
Location
Los Angeles, CA US
10/19/2016 9:13pm
Reasoning for not putting the wall all the way to the ceiling?
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/19/2016 9:35pm
Grizz wrote:
Reasoning for not putting the wall all the way to the ceiling?
Yeah I talked a bunch on it in an earlier post. Basically versatility and errr reliability... half wall let's me carry items longer than 7.5', namely a surfboard. Also if ever I have another lock failure with the cargo doors, this let's me will get back into that area. I also like being able to keep an eye on things as I drive. I might put a removable cargo net between it and the ceiling for added safety but I'm not super worried.
Grizz
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3109
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7/2/2012
Location
Los Angeles, CA US
10/19/2016 9:59pm
john.aron wrote:
Yeah I talked a bunch on it in an earlier post. Basically versatility and errr reliability... half wall let's me carry items longer than 7.5', namely...
Yeah I talked a bunch on it in an earlier post. Basically versatility and errr reliability... half wall let's me carry items longer than 7.5', namely a surfboard. Also if ever I have another lock failure with the cargo doors, this let's me will get back into that area. I also like being able to keep an eye on things as I drive. I might put a removable cargo net between it and the ceiling for added safety but I'm not super worried.
Ah okay I must have missed that post somehow. I don't have a full wall in my van either but I want to put one in because smell.
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/19/2016 10:19pm
Grizz wrote:
Ah okay I must have missed that post somehow. I don't have a full wall in my van either but I want to put one in...
Ah okay I must have missed that post somehow. I don't have a full wall in my van either but I want to put one in because smell.
So far I haven't had that problem.
tomm55x
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753
Joined
9/14/2014
Location
Erie, PA US
10/20/2016 4:18am
This motovan just keeps getting better and better!!
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/20/2016 6:04am
Great work! Enjoy that thing now!
Haha maybe Smile I kind of want to sell it and do another with a high roof.
CarlinoJoeVideo
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7418
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11/30/2013
Location
Portland/Los Angeles, CA US
Fantasy
2561st
10/20/2016 6:44am
Great work! Enjoy that thing now!
john.aron wrote:
Haha maybe Smile I kind of want to sell it and do another with a high roof.
High roofs are very nice. If you are ok with no underground parking or garage, high roof all day.
10/20/2016 8:44am
Those considering a future Motovan build, if your main function is hauling motorcycles, fuel and chemicals that go with..I can't stress enough how important a sealed full wall is. If you add a door or window to the wall, it should also have air tight seal. If just doing short trips to your local riding area, you may be fine without a wall. If you are road-tripping and/or your van also doubles as a camper, sealing off the garage area is essential in my experience.

The wall build on my Van was the only thing I sub-contracted out. I had a professional carpenter build and install the wall. Tailored and sealed to an air tight fit, it also adds overall strength to the chassis for bike support and keeping cargo in the rear in a worst case scenario.


Nice work John, sorry for the interruption, carry on...
Markopolo400
Posts
1392
Joined
7/24/2012
Location
St. Paul-ish, MN US
10/20/2016 2:29pm
I had a van for 4+ years that I camped in all the time with 2 bikes and all their supplies. I never built a wall, and I never had a problem with smelling gas/fumes.
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
10/20/2016 3:05pm
Obviously there are some strong opinions regarding full walls, half walls and no walls. I can say that I've routinely had a bike and gas can loaded in the back and I've never smelled either under normal circumstances. If however, you leave the gas can vent open even a speck, the whole van fill with fumes real fast, haha. If that happens the vent fan is real key!

I think really this comes down to how you personally plan to use the motovan...If you have a carbonated bike that's more likely to leak or a cheaper fuel can, then I'd say a sealed wall is important. If you have an FI bike and a gas can that seals well I don't think its so important from a fumes point of view. In any event I plan to sleep with the vent open, even if I don't run the fan... closed spaces without airflow just freak me out!

Besides fumes there is definitely a safety aspect associated with the half wall. While I have things bolted down pretty well, I'm confident that the pressure washer will turn into a missile in a real crash. This is the motivation for building a cargo net from the wall to the ceiling, and I'll likely go that route before too long.

I appreciate everyone's kind words regarding this project. I've had a blast working on it I'm really proud of the [nearly] finished product.

Now... back outside to work on the curtain.
1
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
1/1/2017 9:10pm
Hey friends... In case anyone has been wondering I've still been working on the van and have even taken it out on a couple extended trips. I'll post another update tomorrow morning. Everything is pretty much set for the Cali Trip starting 3 days from now. Can't wait to show you all the finished product!
john.aron
Posts
85
Joined
7/3/2016
Location
Boulder, CO US
1/2/2017 10:29am
OK Here is the finished product: In total it took 6 months and 1 day. I'm pretty happy with the results.

This week I brought it Denver Window Tint to have the back and side windows covered in white vinyl. I wasn't digging the look of the windows and couldn't figure out a realistic way to replace the doors with those that have sheet metal. This worked well enough and only cost $90.




I tried to make the inside of the back doors as functional as possible. The back left door has all of my aerosol cans. I didn't like the look or the rattle of the sheet metal fixture, so I carpeted it over it and make a shelf along the bottom. This holds the cans tight so they don't fly all over the van when you slam the doors.


The back right door has 2 hooks for post-shower towels.


What's that you say, John? A shower? Of course a shower. I already had all the plumbing 90% done so I through on another valve and a showerhead.

I guess I need one more zip-ty on the trailer wiring harness' green wire...

The drivers side cabinet has been outfitted to be as functional as possible. It holds the tool box on the far right with a 2 burner propane stove stowed behind it. As you move backwards there is a soapy water spray bottle to help in changing tires, a small work bench/workspace, and the pressure washer. Above the toolbox on the far right is the propane heater, with its propane tank on the floor. As you move back there is a paper towel holder with carbon monoxide and dual smoke/carbon monoxide detectors (redundancy) and a pit posse box for work gloves.


In the future I plan to put a sink where that stretch of workspace is. It will tap into the water lines above and drain into the wheel well. It will have a cutting board top such that it can be made a workspace again or be used to prep food... Every cutting board has two sides right?! Laughing

The end of the bench holds the pressure washer hoses and wand as well as an air pump.


On the passenger side there is the right bench, where I sit and put on gear. Towards the back is the push broom, air pressure gauge and fuel storage. This makes filling fuel easy since you can open the right cargo door first without even needing to take out the fuel can.


Looking in straight from the back. You can also see my 7 gallon drinking water storage jug and fire extinguisher at the front of the bench.


The tie downs have hooks on the ceiling to make loading the bike easier and in the center of the floor is ramp, clean/dirty oil storage and a box for my boots.



It holds 3 quarts of fresh oil up front and a bucket for draining oil behind that. You can also see the propane cylinder with its hose. The hose can be connected to either the heater or the stove and is long enough to reach the very back of the van.

Lastly, up front in the bed area I have made a small 4-cubby piece so that I can store my living essentials and shoes while I sleep. I also have a couple pee bottles. Hanging from the ceiling I have a couple carbiners for holding a drinking water bottle or anything else that might be handy.



That about wraps up this project! When I get back from Cali I intend to have the front windows and windshield tinted and it's going to be hard for me to resist putting on the black rims that I want. Its been an absolute blast to make to thing. I already really want to do another one.

All that being said, I am entertaining offers on this van. I'm not in any rush to sell it, by any means... but I really liked this project and I'd like to make another one.

I'll post a few more pictures when I get it loaded for the CaliTrip.

Meanwhile -
Feel free to follow me on instagram or snapchat: john.aron
facebook John Maguire
or send me an email: john.aron.maguire at g mail dot com

If you live somewhere near Vegas on the way from Colorado to SoCal I'd also be stoked on having a spot to park the van Thursday night Laughing

If you live in SoCal and want to get together to ride sometime in the next three weeks or let me park in your driveway also drop a line Cheerful

Thanks everyone for your support!

-John
CarlinoJoeVideo
Posts
7418
Joined
11/30/2013
Location
Portland/Los Angeles, CA US
Fantasy
2561st
1/2/2017 11:03am
john.aron wrote:
OK Here is the finished product: In total it took 6 months and 1 day. I'm pretty happy with the results. This week I brought it...
OK Here is the finished product: In total it took 6 months and 1 day. I'm pretty happy with the results.

This week I brought it Denver Window Tint to have the back and side windows covered in white vinyl. I wasn't digging the look of the windows and couldn't figure out a realistic way to replace the doors with those that have sheet metal. This worked well enough and only cost $90.




I tried to make the inside of the back doors as functional as possible. The back left door has all of my aerosol cans. I didn't like the look or the rattle of the sheet metal fixture, so I carpeted it over it and make a shelf along the bottom. This holds the cans tight so they don't fly all over the van when you slam the doors.


The back right door has 2 hooks for post-shower towels.


What's that you say, John? A shower? Of course a shower. I already had all the plumbing 90% done so I through on another valve and a showerhead.

I guess I need one more zip-ty on the trailer wiring harness' green wire...

The drivers side cabinet has been outfitted to be as functional as possible. It holds the tool box on the far right with a 2 burner propane stove stowed behind it. As you move backwards there is a soapy water spray bottle to help in changing tires, a small work bench/workspace, and the pressure washer. Above the toolbox on the far right is the propane heater, with its propane tank on the floor. As you move back there is a paper towel holder with carbon monoxide and dual smoke/carbon monoxide detectors (redundancy) and a pit posse box for work gloves.


In the future I plan to put a sink where that stretch of workspace is. It will tap into the water lines above and drain into the wheel well. It will have a cutting board top such that it can be made a workspace again or be used to prep food... Every cutting board has two sides right?! Laughing

The end of the bench holds the pressure washer hoses and wand as well as an air pump.


On the passenger side there is the right bench, where I sit and put on gear. Towards the back is the push broom, air pressure gauge and fuel storage. This makes filling fuel easy since you can open the right cargo door first without even needing to take out the fuel can.


Looking in straight from the back. You can also see my 7 gallon drinking water storage jug and fire extinguisher at the front of the bench.


The tie downs have hooks on the ceiling to make loading the bike easier and in the center of the floor is ramp, clean/dirty oil storage and a box for my boots.



It holds 3 quarts of fresh oil up front and a bucket for draining oil behind that. You can also see the propane cylinder with its hose. The hose can be connected to either the heater or the stove and is long enough to reach the very back of the van.

Lastly, up front in the bed area I have made a small 4-cubby piece so that I can store my living essentials and shoes while I sleep. I also have a couple pee bottles. Hanging from the ceiling I have a couple carbiners for holding a drinking water bottle or anything else that might be handy.



That about wraps up this project! When I get back from Cali I intend to have the front windows and windshield tinted and it's going to be hard for me to resist putting on the black rims that I want. Its been an absolute blast to make to thing. I already really want to do another one.

All that being said, I am entertaining offers on this van. I'm not in any rush to sell it, by any means... but I really liked this project and I'd like to make another one.

I'll post a few more pictures when I get it loaded for the CaliTrip.

Meanwhile -
Feel free to follow me on instagram or snapchat: john.aron
facebook John Maguire
or send me an email: john.aron.maguire at g mail dot com

If you live somewhere near Vegas on the way from Colorado to SoCal I'd also be stoked on having a spot to park the van Thursday night Laughing

If you live in SoCal and want to get together to ride sometime in the next three weeks or let me park in your driveway also drop a line Cheerful

Thanks everyone for your support!

-John
Awesome man! I hit you with a follow on a Instagram. Bummer I'll be gone the next few weeks, would have been fun to link up. Make the drive to Zaca station. Let me know if you need the owners contact info to reserve a spot.
Huckster
Posts
2581
Joined
8/15/2006
Location
Woodstock , NY US
1/2/2017 11:32am
Just curious, why not a full wall divider?
tomm55x
Posts
753
Joined
9/14/2014
Location
Erie, PA US
1/2/2017 11:41am
great build, one of the nicest and detailed builds I have seen.

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