Howdy!
Greetings from sunny Portland.
I recently finished a significant renovation to my passenger wagon, and wanted to share photos and info here. This forum was a constant source of info for me, and I am very aware of the challenges of a passenger van conversion now. Posting here to show my solutions to some common challenges and share my build. Not the straightest cuts or fine detail, but I'm thrilled with out it turned out.
Airbag navigation -
Did not want to remove or fiddle with the sensor tricking. It was actually pretty easy to mount what I was using for studs, 1x2s, above the airbag and around the components down the whole side of the van. From there, I used metal braces to 'hang' a 1x3 below the airbags. It's super solid, and I wasn't expecting it to work this well. This creates a clean gap for the airbags while keeping them out of sight.
Sunroof -
Yep, got a van with a sunroof. Cedar tongue and groove was placed to fit on the inside of the original sunroof outline. For those that know, the glass actually goes from wall to wall inside the car, so adding studs around it was not an option. The side planks are actually supported on the front end by the cross beam where the curtain is. The motor for the sunroof slider is up front, so not involved at all. Functions perfectly.
Cross beam, curtain, extra storage shelf -
I knew I wanted to extend the overhead storage cubby, as I've seen in many conversions, but as with everything on this van it was a puzzle. The cross beam itself is held by the aforementioned studs above the airbags, very solid. I also didn't want to cover the sunroof entirely, so adding the shelf over just the passenger side was my solution. It also helped reduce the head bonking when climbing from the driver seat to the back. I'm not trying to be incognito with this van, but it can work with this curtain. Its main use is to keep the back of the van impossible to see when parked at trailheads, parking lots, etc. Rear windows are all 5% tint as well to aid in this.
Bed side wall -
Minimal effort went into this side, will be covered with bed/couch cushions and largely unseen.
Slider bed -
1-off made by a conversion company that ended up unused on someone else's rig. Lucked out with some connections for this one. Much lighter and smoother than what I would have built.
Things I'm using:
Goal Zero Yeti 400 + Boulder 50 solar panel mounted up top
Standard LED puck lights + sting lights as recommended by most all van folk
Alpicool C20 fridge - best bang for your buck fridge on the internet. ~2-5 watt power draw once at temp
Basic hand pump faucet + dog bowl converted sink
LED dimmer switch - https://www.amazon.com/dp/B00FAAPHQW?psc=1&ref=ppx_yo2_dt_b_product_details
Fuse box - https://www.amazon.com/dp/B092LSB9HF?psc=1&ref=ppx_yo2_dt_b_product_details
Small dimmer switch for under sink lights - https://www.amazon.com/dp/B07Y2XC225?psc=1&ref=ppx_yo2_dt_b_product_details
Reading lights (mounted lights next to curtains) - https://www.amazon.com/dp/B09BJ2GMVP?psc=1&ref=ppx_yo2_dt_b_product_details
Fan - Ventline Vanair
Happy to discuss further or offer insight where needed. I don't have many photos of the build process unfortunately.
Happy travels.
Cheers
