August Project Update

Friday, August 1st, 2025

July hasn’t exactly been the most productive month for the van build — and the blame mostly falls on the weather. With daily temps regularly hitting 90–100°F, working inside a metal box on wheels has been rough. That said, van builds are fluid by nature. Plans change, timelines shift, and ideas evolve — and this past month has been a great reminder of that.

Here’s what’s actually gotten done — and what’s coming next.

Roof Rack & Solar Panels

The roof rack install is finally underway. I mounted the front wind fairing and a rear crossbar earlier this month, and since then, the solar panels have been mounted to the rack — a huge milestone. I haven’t had the chance to run the wiring through the roof yet (waiting on the new solar entry gland), but that’ll be a project for next week. Once that’s in, the system can start taking shape.

Kilmat Sound Deadening

This part was straightforward. I installed Kilmat sound-deadening panels throughout the van to reduce road noise and eliminate metal-on-metal rattling. It’s a small step that goes a long way toward making the van more livable, especially once everything is built on top.

Rivnuts/Crossnuts (aka Threaded Inserts)

Originally, I planned to use threaded inserts to mount furring strips and other components to the van’s frame without drilling directly into the metal. But after multiple issues with the install tool — and the time it was going to take — I decided it just wasn’t worth the effort. I’ll be moving forward with more traditional mounting methods instead.

AC Unit Installed

I picked up the EcoFlow Wave 3 — a portable AC unit that can both cool and heat — and added a window adapter to vent the hot air out. While this setup isn’t permanent, it’s made the brutal summer afternoons a little more bearable while working inside the van.

Subfloor Progress

The subfloor is mostly finished. The 3 panels are down, and next week I’ll be cutting out holes to expose the OEM cargo tie-down mounts. I plan to keep these functional in the final layout for flexibility and added utility. For the subfloor I used (3) 4'x8' sheets of 1/2 inch baltic birch, cut to size. I was able to use the included rubber mat from the van to trace the edges and curves of the van, to cut them with a jigsaw (which I had to go out and buy for this project). I don't plan to mount these anywhere.. baltic birch is heavy already, but I'm expecting most of the furniture and other items I'll be installing will hold this subfloor down well enough. Absolute worst case, I may glue it down. I'll make that decision once the cargo tie-down holes are cut, which will give me a good idea of how flat the subfloor will be.

What’s Next (August Goals)

If the weather holds (and unfortunately, it probably will), August is shaping up to be another scorcher. Progress may be slower than I’d like, but here’s what I’m aiming to complete:

• Insulation: The 3M Thinsulate is here and ready to go. It’ll be installed on the walls and ceiling to help with both temperature and sound control.
• Furring Strips: Now that the subfloor is nearly wrapped up, I’ll be working on the wall and ceiling furring strips. These will form the foundation for future wall panels, cabinets, and electrical mounting points.
• Solar Wiring: With the panels mounted, the next step is cutting into the roof and wiring everything to the power system. Once the gland arrives and weather cooperates, I’ll get this wired up.
• Power System Redesign: I’ll go into more detail soon, but the electrical setup has completely changed. I’m now going with a hybrid system: part hard-wired, part portable power station. It’s the best of both worlds — permanent infrastructure where it counts, with flexibility to disconnect or move things around when needed.

Coming Soon

I’ll post another full build update in early September, with smaller updates along the way. Things are moving a little slower than planned, but that’s just how van builds go — especially in the middle of a Midwest summer.

Stay tuned.