Putting Up Walls in the Van! Ram ProMaster Van Build Conversion – Episode 10 | Jason Klunk
In this article I go over how I did panels for the walls in my ProMaster.
I used ¼” birch plywood on the area where it’s going to be covered by cabinets. I used ½” birch in the back where my bench seats will be. There is nothing complicated about this process, just watch out for your bolts in your furring strips.
Sometimes it’s hard to picture how everything is going to turn out, but this is a nice little baby step for getting to see a few things come together.
1] Using kraft paper, create templates for your wall panels.
2] Cut out the panels using a circular saw and jigsaw.
3] Get the panels in the right spot, predrill your holes (make sure to watch out for the bolts in the furring strips), and then screw the panels into the furring strips.
Framing the Van w/ Furring Strips! Ram ProMaster Van Build Conversion – Episode 9 | Jason Klunk
In this article I go over how I framed out my van. Most spots I had to double up my 1/2” birch plywood to create 1” strips. In some places I used 3/4″ poplar and some places it was built up 2”. It really all depends on how you are trying to lay out your walls, what you want flush, what you’re doing with the weird awkward beams, etc. I had specific areas I needed flush so mine may be different than what you are doing.
Crossnuts/plusnuts are great when they work and horrible when they don’t! Make sure you double/triple check your installation before you put a bolt in them! The Astro 1450 Plusnut tool is well worth the money.
2] Using the Astro 1450, install cross nuts throughout the van. Take advantage of the existing holes in the van, but drill new ones if you need them in a certain spot.
Make sure you get these installed correctly. Before attaching any plywood, make sure you can get a bolt in/out a few times without the cross nut spinning. If it’s spinning, it’s not installed correctly or tight enough.
3] Determine where you’re going to need studs for you walls/cabinets/etc, and install furring strips using bolts going directly into the cross nuts.
4] For the ceiling in the front/back of the van you have to get a little creative so that your ceiling isn’t just danging on the ends. In the front of the van, there is another stud you can hit. You can either remove the headliner and install a furring strip underneath like the rest of the cargo area, or you can hit the side with some custom pieces.
For the back, you can drill into the back of the van, rather than the ceiling. Just watch out for the light/rear camera wires.
I used a variety of wood in this part of the van, but mostly 1/2″ birch plywood and poplar 1×3’s.
Building a DIY Solar Panel Roof Rack! Ram ProMaster Van Build Conversion – Episode 8 | Jason Klunk
In this article I go over how I built a rack for my Renogy solar panels and attached the rack to my ProMaster. This rack is a nice middle ground for my van. I don’t have a ton of holes in my roof, the rack works well/feels sturdy, and it will allow me to upgrade later on if I want something nicer.
1] Fabricate 4 more plates that are similar to the weatherguard plates.
2] Install the weatherguard roof rails. Make sure to slide in your custom pieces for the roof rack before attaching the rails.
3] Cut the aluminum angle crossbars. Make sure to use a saw blade specifically made for metal if you are going to use a miter saw and also make sure they are clamped down securely.
4] Drill holes into the aluminum angle so that you can attach the angle to the solar panels. Use the existing holes in the solar panels to figure out where to drill the aluminum.
5] Drill holes into the aluminum angle so you can attach the angle to the roof rails.
6] Attach the aluminum angle to the solar panel(s) using stainless steel hex bolts, washers, lock washers, nylon bolts, and Loctite.
7] Drill a hole in the roof for where your solar panel cables need to come down. Try to put them as close to where your solar charger will be.
8] Drill out the holes in the rubber of the cable clam. You’ll want to start really small and then gradually get bigger drill bits. Pour water on the drill bit/rubber as you are drilling so you don’t burn/rip through the rubber.
9] Thread the solar panel wires through the cable clam.
10] Attach the cable clam to the van. Do a spray test to make sure you aren’t leaking anywhere.
11] Attach the solar panels / rack to the roof rails.
