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2004 Chevy Express 3500 15 Passenger - Decided I wanted a Chevy Express van, primarily for the better fuel economy but also for the design. I elected for the extended too since the two extra feet could come in handy.
The walls were filled with 1" hard foam and held in place with expansion foam. If I were to do this again I would elect to use spray foam instead, the time savings alone would be worth it. The paneling is 1/4" plywood with a good face.
Messy and time consuming
The floors have 3/4" hard foam insulation and a 1/2" plywood sub-floor. The sub-floor was screwed into the chassis with 1.5" stainless steel lag screws, which were counter sunk into the wood. Then a layer of wood filler and one foot square vinyl tiles.
Windows & Blinds
The blinds were custom made from blackout cloth and standard window rods.
Rear under-bed drawer with 200lb capacity. Front drawer to access other side.
Fridge installed. Perfect height with not an inch to spare. Powered by a 1100 watt Krieger inverter.
Extremely happy with the lights, almost always ran them at 1/4 power during the trip. Lights were 3 watts a piece and 240 lumen.
Hidden toilet that we never ended up using but is still nice to have.
- Camco travel toilet
Compact and easy to use
Bowl slowly fills during driving