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.

Part-time travel van

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.

  • https://www.homedepot.com/p/100549260
    Cheap 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.

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

See more here:

Website https://imgur.com/a/mZX5Y

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