Renovation

Let’s Refurbish a Van – Part 8: Hood Scoops (By Andy)

A post by Andy

{Modified the title theme some. We think of ourselves much more as a big van than a small RV. I now want to start prefacing this and future posts to be more representative of our self-image.}

So, to the meat of the subject. I just finished our hood scoops! Why did I make hood scoops? Well, for one, they look pretty cool and I needed a prominent place to put my new go-fast emblems that I ordered from Amazon.

Mainly, we are trying to get as much power out of the engine so we can get our heavy old self up the high steep hills. In that vein, I have been playing with the spark timing, carb mixture, and intake airflow. By tweaking and adjusting these parameters we are working to get the most power and efficiency out of our old engine. Specifically, advancing the timing can get the engine to produce more power, but too much spark advance causes engine problems—pinging and preignition. If the engine is cooler, one can run with more advance. Another way to look at it is that with a given timing advance, if the engine and intake air get hotter, then the timing is too far advanced.

Maybe a side note about my “go-fast” emblems. Car companies try to sell cars. Sometime fancy cars come with racing stripes, cool graphics, and badges on the side about engine stuff. A joke among car people is the question “How much horsepower do the stripes add?” The answer is, of course, none. But… they do look cool. Look around, they are everywhere: M3, AMG, Hemi, 440, HiPo. The only thing the badge or stripes could actually do is add an immeasurably small increase in drag, or some unneeded paint weight. They are simply for the people in the car next to you. All the same, they look sporty, so I bought some that state the displacement of our engine and say it is “High Performance”. What I’m saying here is they do nothing, but they truly do look great!

So, I wanted more air to get in and out of the engine compartment to cool the engine, and have the air flowing into the air cleaner be as cool (and dense) as possible. To make sure I had an understanding of the pre-hood-scoop environment, I first taped the probe end of my digital temperature gauge to the air cleaner. Over a few weeks in different driving conditions and different altitudes, we took notes about the temperature measurements of the air cleaner and air filter. You can see the wire to the probe, and the tape holding it in one location.

Overall, we are in the 150º–160ºF range under the hood after the engine gets warmed up and when the ambient temperature is in the 70º–80ºF range. So, to get more outside air in and more inside air out we need some kind of venting. I looked online, and $50+ plastic vents and scoops can be found, but they were not really van-sized, and seem flimsy. Metal ones can also be found, but are more expensive, and again, really don’t fit. Apparently there is an untapped market of people who want to mod 1985 Ford vans! (Investors be wary—the market may be small.) I finally hit on the idea that rectangle cake pans are about the size I wanted, and they are inexpensive, and they are made of metal designed to withstand 500ºF+. Going with this thought, while we were camping in El Malpais National Monument, I made some cake pan-sized cardboard mockups and spray painted them with a blue that I had.

Test fitting…

I thought that looked good, so a few days later when we were in a town, we got some cake pans.

One morning, a few weeks later, when we where camping at the Great Salt Lake, I got out the pans, tin snips, sandpaper, and primer, and got to work remaking our sweet cake pans into even sweeter performance hood scoops (please note the word play).

Here they are.

Test fitting.

We stashed them away for a bit and traveled onward. Another week later we had a free day while visiting our friends the Higdems in Kimberly, ID. I measured, moved, marked, measured, and measured and marked again. Then I started drilling holes in the hood.

Lots of little holes now!

After fitting and drilling the mounting holes, I now knew what piece of the hood (bonnet, for any Brits out there) to cut out. Out with the jig saw.

Another side note here: When putting the Turtle together, we set ourselves up with a few DeWalt cordless tools and the battery charger that plugs into a 12V cigarette lighter. The tool charger is now wired to our solar-charged batteries, so we are using the sun’s energy to drill, cut, and modify our hood. It feels fun to know that when working on projects such as this!

For the final install, I put down a small bead of RTV sealant, aligned the scoops, and screwed in the 6 screws per scoop that I had already pre-drilled. After the RTV cured a bit, I got out our boat paint and went at it.

Included above is, obviously, a photo of what Scout and Gracie were doing at the time. A few days later, at Dave and Ryann’s place, I added more RTV to smooth the transition and put on more paint to finish it all off.

All finished now, after the last painting and with the great go-fast badges installed.

We should call this the conclusions section of the post, for you science people out there. Well, they have been on now for a week, and we don’t move fast, so we have only driven a few hundred miles. We will need to collect more data, but so far the maximum under-hood temperature we have seen in 135ºF, and most of the time it has been in the 100º-120ºF range (and we are actually in hotter weather than when we took our non-hood scoop measurements). We have also driven through crazy heavy rain and, as expected and hoped for, the small amount of water that enters through the scoops has no adverse effects on the engine. Generally, a pretty solid success, and I have since advanced the ignition timing just a bit with no pinging.

Oh, maybe a cost breakdown. The sum total of the cake pans, primer, quantity of screws, RTV, and paint used is less than $20. The go-fast badges were $11 each. Dave suggests I sell it as “The whole project was less than 45 dollars.” I think I shall adopt that tract!

All that for less than 45 dollars!!!

Let’s Refurbish a Van – Part 7: Our Batteries Phase 1 (By Andy)

A Post by Andy

{Note: The work detailed in this part of the post was completed over the summer of 2015, before we moved into the Turtle. I am just getting to writing the post now.}

So, we like to have our computers run, have lights, have the controls for our fridge work, have a charged Wi-Fi hotspot, and have our furnace fan powered to keep us warm. For all this we need electricity, and since we want to be off-grid, we need batteries. We started with this:

If you are familiar with the Turtle, this compartment is behind the largest access door on the passenger side- the door with the vent in it. In the following photo, I put in a dotted line where the plane of the floor on the inside intersects the compartment.

The walls of the compartment above the floor line are plywood, and bump up under the couch inside. The sides and bottom below the line are made of heavy steel. I have deduced the compartment was originally designed for a generator, as there was old 120V AC wiring running to it, an unconnected fuel line that ran into the back, and the door vent.

I had a hard time figuring out what all the wires were hooked to, as it was a bit haphazard in the compartment. In the above picture, (1) is a port that goes outside, below the floor of the Turtle. The wires there threaded out of the box, ran a short distance under the Turtle’s floor, then threaded up through the floor to the old inverter. There is a second hole (2) that the wires from the old 100W solar panel and the wires between the battery and main 12V distribution panel were run. (3) is the unused electrical box that had 120V AC wires run to the compartment where the shore power cable is housed.

Maybe I should back up a bit and throw out a few concepts and definitions and explanations for the terms we will be using.

Battery: A thing that stores electricity in chemical bonds. Here, we are just referring to 12V lead-acid batteries.
12V/12VDC/DC: 12 Volt Direct Current (DC). This is what cars use for their electricity for headlights, the radio, starting, etc. It is the kind of power all the batteries we talk about will produce.
120v: 120V Alternating Current (AC). This is what is in your house and in businesses you know, the typical wall plug Amy and I look for at restaurants to plug our computers into. It’s generally 120, 121, or whatever it takes.
Current: The flow rate of electricity.
Voltage: The force pushing the electricity through the wires.
Inverter: An electrical box that changes 12VDC to 120VAC. It changes car electricity to house-hold electricity. This is so we can plug our AC computer cords into our DC batteries.
Converter: An electrical box that changes 120VAC to 12VDC. The opposite of the above—pretty much a garage battery charger that you use to get your car started after you leave the lights on.
Charge Controller: An electrical box that changes the output of the solar panels into DC voltage, hopefully charging the house batteries.
House Battery: Now, I probably use this too freely. When I talk about house batteries, and I mean batteries dedicated to our living compartment. If I say house (or household) electricity, I mean 120 V AC. Got to figure this out… but, house batteries are 12V batteries separated from the car system, and dedicated to lights and heat and powering the inverter in the house part of a van. One should be able to run these dead flat, and the car will still start, as they are fully independent circuits.
Starting Battery: The batteries under the hood, used for starting the car, sparking the gas when the engine is running, running a radio (if you had a functional one), and lighting the headlights.
Shore power: Kind of a boat term, but a source of 120V AC electricity you can plug into. When you pull up at a friend’s house, and pull out your extension cord, and plug into their electricity, they are your “shore power”. (Thanks Alex and Julie, Kari and David, Connie, Mag and John, Dave and Ryanne, Mike and Becky, Blake and Martha, Roger and Mary, Chris, Dad…)

Now, back to the good stuff! To start the battery box rebuilt and modification, I first labeled the wires and removed the old battery. I then cleaned the compartment with baking soda and water to neutralize the sulfuric acid and prevent further corrosion. Lucky, the metal compartment is super stout, so it was still in great shape. As usual, after a final thorough cleaning, I caulked the seams and painted the compartment with black Rustoleum. I can’t find a picture of the completely empty, cleaned and freshly painted compartment, but trust me, it looked good!

After getting the compartment beautified, I cut and painted a plywood plate to fit into the bottom, bolted and glued it to the metal base of the box, and mounted battery trays to it. I painted up everything with oil-based paint and used stainless steel hardware to affix everything.

Since we had just gotten the Interlux blue boat paint, I practiced the painting technique on the top surface of the plywood base, so it is the same shiny blue as the Turtle exterior. In the following photos, you can see the two new Fullriver 115Ah 12V DC sealed AGM batteries that we started with in there, but just patched into the cleaned up existing wiring we are reusing at this point.

I decided to go with Absorbed Glass Matt (AGM) batteries. They cost a bit more than flooded batteries, but they do not spill, they will not develop corrosion at the terminals, and can be mounted sideways, if that configuration seems important. Additionally, they do not require venting, so they can be safely installed inside the living compartment, if that is necessary. Here is the site. We have been happy with this choice, and as you will find out in future posts, choosing AGM sealed batteries will allow us to make some future cold-weather modifications.

As to wiring, I was just starting to adopt the boat convention for new circuits and runs I would rewire. The convention is as follows: For 12VDC, yellow is ground, and red is positive. For 120V AC, the wires are white, black, and green for ground. Examples of the wires are here:

The reason behind adopting this convention is that at a glance, you can tell which circuit they are supposed to be wired to. Additionally, the boat 120V cable is stranded, as opposed to the household solid copper wire. Stranded wires should always be used in a vibration environment. Logically, then, a van should have no solid copper wires (though most RV builders do actually use cheaper solid copper for the 120V runs). As you might have observed, we have concluded that one should think of their van as a boat, and look to boat paints, wires, latches, and hardware for the upgrades and work. Though the boat cable is a little more expensive, it is paired and tinned for corrosion resistance, and gives a real nice finished look. Additionally, it can be purchased in any gauge.

So, at the end of our Phase 1 battery configuration we had our two new AGM batteries with a combined storage of 230Ah at 12V installed and secured, with the connections cleaned up. With this battery pack, we simply used the old converter to charge them when we were connected to shore power, and the old inverter to make our 120V for our computers when off-grid. At this point in our journey I also had just finished the install of our 300W of solar to charge the batteries (we will cover the panels and solar charging and solar controller in a different post).

That’s Phase 1 for you!

Let’s Refurbish a Van – Part 5: Suspension (By Andy)

A post by Andy.

{Note: The work detailed in this post was completed over the summer of 2015, before we moved into the Turtle. I am just getting the time to write the post now.}

We wanted a little more ground clearance, fender and frame spacing for the taller tires, and a good, safe ride. We initially hoped to find an off-the-shelf lift kit. . . no soap. People make them for Ford trucks and Broncos, nothing for 80’s vans. I suppose that makes sense; the van market must be pretty small. So I guess we’ll just have to design and install a complete suspension overhaul and customization ourselves. This is where we started…

In the front we have what Ford calls a twin I-beam suspension with what I infer is an aftermarket sway bar, and the rear is just a simple leaf spring configuration, though there are functional aftermarket Firestone airbags that have been added.

Let’s address the rear first; that is comparatively easy. We found some 2″ lift blocks from Action Van (http://www.actionvansuspension.com), that fit between the axle and leaf spring. Action Van actually makes full lift kits, but only for ’92 and newer Ford vans. Lucky, the rear suspension was the same, so we were able to use their blocks for the back.

With some breaker bars on the end of the socket wrench and a little groaning, the blocks were pretty easy to install. Lots of jacks and heavy-duty jack stands were employed in this step! Here is a poor photo of the suspension when I was starting the modification.

Here is a photo of the installed blocks. Always remember that it is a good idea to drive a bit and then retorque all the bolts for suspension components after making changes- things can settle under the vibration.

After adding the lift blocks, the rear airbags were adjusted by cutting, drilling, and painting 2″spacers from hollow square tubing and bolting into place between the axle and bottom of the air bags with new grade 8 hardware. Sorry for the bad photos (at the time, the important thing was to get stuff done, so the documentation suffered), but what you can see in the following is the original airbags and the blocks and hardware cut, drilled, and painted.

And a current photo of the final installed version- a little dirty, as we have been trekking about for a little over a year now.

Pretty straight-forward modification, and after a few thousand of miles everything is very solid.

Now the front suspension. The modifications needed were: 1) taller coil springs 2) adding air bags 3) fitting the new shocks 4) dropping the sway bar 5) dropping all 4 I-beam pivot points 6) replacing all the suspension bushings in the process.

I was able to find taller MOOG coil springs and front airbags, cranked everything apart, and got those pieces installed.

You can see that at this point with the added spring height but no change to any of the I-beam pivot points, the camber is extreme.

The next step was to remove the suspension mounts. This was a true pain, as there were many frame rivets to remove. Depending on the accessability, I would drill, grind, hammer, cold chisel, or simply swear at for long enough to remove. I would consider it a solid success if I came home from work, spent all evening, and got only one removed. I blocked it out, but there were somewhere between 16 and 20. Anyway, after getting the pivot points removed, I made some drawings describing the desired changes needed to drop the pivot points 2″ lower, then took the parts to a fabricator. I weld myself, and made the grill guard, and all other metal modifications on the Turtle, but I wanted really great welds on these parts, so we paid to have someone with more skills do the modification. Plus, it was pretty darn magical to just drop the parts off and pick up the finished pieces a few weeks later. So, some of the suspension pieces back from the welder:

Painting, almost ready to install. I had ordered new MOOG bushings for all the pivot points, so these were installed at this point too.

Except for reusing a few special Ford bolts, the bolts and frame rivet locations were replaced with 1/2″ grade 8 hardware. Some current pictures of the completed front suspension.

Here is a photo of the dropped sway bar pivots with the new greasable bushings installed, again, everything is grade 8 hardware. I never buy anything else (except maybe stainless for chassis fixturing or the interior).

New Bilstein shocks were ordered for all four corners. The stock fit for the rear has enough travel to handle the 2″ lift, so we got the heavy-duty RV ones, and that was easy. We had to calculate the new front geometry to size the front, and went extra fancy with the front shocks and got an external reservoir setup. They look cool! (I ordered them from shockwarehouse.com, part number 25-177480 and 24-184663.)

Here is the front suspension a year into our travels. I was replacing the brake pads, so I took the opportunity to clean everything up, and also paint the hub with Rustoleum. We have had no problems with the suspension thus far.

The lift was added to enable us to have the taller tires, and to have more ground clearance. There have already been a number of cases where we figure we would have likely damaged something on the underside if we did not have the clearance we have. Additionally, with the clearance and narrow tires, we have made it through some pretty deep snow without problems. It has proven to be a successful modification. Plus, it makes the Turtle look cool!

Andy Wears Shorts in the Snow: Christmas In South Dakota

Happy New Year, everyone! Woo hoo!

2016 was a super exciting year in the Turtle, and the coming year should be equally full of challenges, victories, and vistas (and frisbee sessions for Scouty).

Before I get into our plans for the upcoming months, let’s catch up with some photos of what we’ve been up to since we left Yellowstone National Park last month! Since that very chilly week living in single-digit temps, we’ve learned a bunch about what we needed to do in order to better winterize the Turtle. So before we left Montana, we headed back to Mom’s house in Bozeman and got busy buttoning everything up with layers of insulation over the windows, extra curtains to divide the colder cab and loft from the warmer living portions of the Turtle, and some modifications under the hood.

Naturally Andy was in charge of the under-the-hood tasks, and he spent the week in Mom’s garage finalizing work on the second alternator. With that new addition we can charge our house batteries while we drive, as the solar panels aren’t getting a lot of sun in these winter months. Not surprisingly, this guy took the opportunity for a wiring project and really brought it to the next level. Give an engineer an electrical mission, and he’ll buy all the toggle switches Home Depot has in stock and create a panel worthy of the dashboard of a UFO. I still need to take a photo of the installed panel, but the process picture gives you a pretty good idea of the extent to which this guy takes on a project!

Meanwhile, in between my winterizing duties, I got an extra week to hang out with my mom, sister, brother-in-law, nieces and nephews. We crafted, played video games, and I took on a request for a Photoshop job: Clive wanted to see himself in his “boat” on the water. . . “with a beard!” Turns out that kid could totally pull off a beard.

Even Gracie appreciates how awesome these kids are.

The snow continued during our stay, much to Scout’s delight. This border collie LOVES snow! He leaps through the drifts with abandon, and runs back and forth between us, trying to encourage us to run along with him.

Gracie, on the other hand, finds the warmest covered spot and settles in.

After getting used to living as locals, it was hard to leave all my favorite people. It was such a treat that we were able to spend so much time with them though. In the Pre-Turtle days, we were typically limited to a week each year at most for visiting family. So I can’t get too greedy when I just got to hang around for a whole couple of months!

Once the improvements were complete, and I felt confident that the kids were ready to love The Legend of Zelda without further encouragement from their auntie, we left Bozeman. After a quick stop in Billings to see Blake, Martha, Harper, and Grant, we then made our way toward South Dakota. We drove by Little Bighorn Battlefield right before it closed for the day, and took a brief walk through the grounds as the chilly winter sun set.

Then with the heater on full blast, we moved on to Gillette, WY for the night where I got so unbelievably sick. (I’ll only include this because I promised in a previous post that I wouldn’t overlook the portions of full-time vandwelling that are challenging, and this was just AWFUL.) I’ve gotten sick a few times since we moved into the Turtle, but they were mostly mild illnesses that were inconvenient but tolerable. I’ve never gotten violently ill while living in the Turtle until that night in Gillette, and it definitely was more challenging than getting sick in a house.

I thought I had food poisoning, as I got sick so abruptly, but in retrospect I think it was likely a severe flu. I was vomiting so much all night (essentially into a pit toilet) that I got massively dehydrated, and unfortunately since we were in freezing temperatures our water tank had frozen and cracked and we had been carrying water around in jugs. As luck would have it we were low on water that night, so I was rationing water and sucking on ice cubes and trying not to step on Andy on the pull-out couch as I got up every 20 minutes to vomit. And the next day we had to move along, so I was sleeping fitfully on a bed rocking and bumping at 65 mph on the freeway. Glamorous!

So, there you go. Full-time vandwelling is not all roses. But for the record, I’m not trading it for anything!

At any rate, while I was in my sicky fog Andy got us to Spearfish in time for Christmas with his family. Much to Scout’s delight, the ground was covered in snow, with a whole bunch more in the forecast.

And much to Andy’s delight, there were plans to assemble a Lego train which would travel around the Christmas tree! I’m not sure how many total man hours were spent around the table between Will, Ellie, Andy and myself, but Andy outshone us all with his dedication to the cause, as well as his impressive Lego skills.

Between the four of us we created quite a spectacular Christmas train, if I do say so myself.

Ellie and I worked on Rudolph’s Christmas Car which led the way, and created bunches of Lego presents. Will put together the engine, the middle cars, the flatbeds, and made a magnificent cubist Christmas tree. Andy made a tippable car that he’d originally intended for imaginary molten metal, but that Ellie and I filled with our gifts instead. He also made a caboose equipped with a crane to hoist and deliver the packages, and it really works, and it’s awesome.

Each day we were surprised by the dramatic change in weather. One day: blizzard. (Andy wore shorts all day.)

The next day: sun.

The next day: more snow.

The next day: more sun!

Snow.

Sun.

You get the idea.

Highlights of our time in South Dakota also included:

Testing out the newly-wired Hella lights. . .

Learning about the difficulties of dumping tanks in winter when all the RV sites for miles around are closed for the season. . . (For those interested parties, it includes making friends with the on-site owner of a closed RV site and graciously being given permission to use the facilities if you can find it and not break anything, digging through the snow until you find the port, boiling hot water, filling a container with hot water, pouring it over the frozen cap until you can open it, taking a photo while your significant other waits for your assistance.)

Being co-planner for a stuffed animal beach wedding. . .

Waiting to see how Andy will alter the “LOVE” Valentine’s decorations his sister put on the mantle. . .

Towing stranded passengers out of a snow drift. . .

Finding Gracie tucked into cozy spots on the coldest days. . .

Scout just driving around town. . .

And knowing Christmas is officially over when you see the Christmas tree ablaze.

Coming up: We’re done with snow and are going to Mexico!

P.S. If you enjoy following along with our blog, don’t forget to click the “Follow” button, and you’ll get an email whenever we post! 🙂

Leaving Bozeman Harbor

We’re back on the road! It’s super, super exciting. When you’ve spent a year roaming and adventuring and then suddenly sit still for a while, the call of the road is stroooong. But even though we were looking forward to moving on down the road, we got a lot of valuable things accomplished in Bozeman Harbor, mostly lots of family time, and it was two months very well-spent.

We originally posted up for a bit to do some Turtle work before winter hits, and after a year of being in the Turtle, we finally finished the bathroom! Andy really killed it on the vanity and faux toilet tank. The “tank” is actually storage (our favorite word these days), but he even made a little flusher you can pull, whose only practical function is to be charming. Andy always goes the extra mile!

You could say it’s come a long way from when we first bought the Turtle. . .

I’d like to make it clear here that it didn’t look like the above photo while we’ve been living in it. . . That’s a BEFORE “before” photo. 🙂 We got a good amount of progress done before we hit the road, but as you can see in the photos below, the vanity was still completely inefficient for storage and took up a ton of room in the small space. And we still had that sink in there, which we didn’t find useful since there’s a kitchen sink three steps from this one, and we’d rather have the storage! But with all the work we had to do in the rest of the Turtle before hitting the road, this portion of the renovation was put on the back burner.

But now it’s done! And we loved our extended stay in Bozeman. We parked the Turtle at my Mom’s house, and while Andy reveled in his huge garage/shop space and engineered all kinds of new fancy Turtle improvements, I got to spend lots of quality time with my mom, sister, brother-in-law, nieces and nephews. I had the best time getting to be a local for a while, and my love tank is filled to the brim. 🙂

We even had a pasta party night, where we made homemade 4-cheese ravioli, sausage ravioli and fettuccini, and three kinds of sauces. If you’re thinking about inviting me to a party, I can promise I’ll come if it’s this kind of party.

We had a fulfilling and productive stay in Bozeman, and I was only able to leave knowing that we’d be back for one more short stint since I have to return on the 8th to ~~walk the green mile~~ go to a dentist appointment. In the meantime, let’s go to Yellowstone National Park!

Let’s Refurbish a Van – Part 3: Tires (by Andy)

A Post by Andy

Maybe you noticed the tires. Maybe, like me, you love tires. We have fancy tires, and I would like to tell you all about them. Let’s start with what we had.

Pretty standard look for an 80’s era Class-C RV. The Turtle’s stock tire size was 215/85R16 on 8-bolt Ford rims. Single wheels in front, and dully rear.

We wanted to be able to go most everywhere, up dirt roads, over snowy passes, through water and mud, so we wanted a taller tire for more clearance, with an aggressive mud and snow tread. Also, as a general rule I am a fan of tall, skinny tires. Pizza cutters, some people refer to them as. Lots of trucks these days have big, fat tires, and they look pretty cool, but for most conditions they are less than ideal. I really like the Cooper A/T3 tread and have run it on other vehicles, so that was the choice for sure. As to the size: to get added clearance, a greater load rating, and to keep it nice and narrow, we went with 235/85R16.

Image source

The new tires are almost 32″ tall- a significant improvement over the stock height of about 30″- so we gain almost an inch of clearance with the new tires. Additionally the 235’s have a load rating of 3042 lbs per tire vs. 2680 lbs for a typical 215. The additional load rating does not increase the load we can carry, but it is just a stronger tire so they will live a long and happy life rolling along far below their load limit.

After selecting a tire and size, special consideration was given to the rims. It seemed reasonable to replace the 30 year-old rims, and due to the tire size change, this was actually necessary. You see, dual tires need an air gap between them to stay cool. The gap is a function of how wide the tires are, and the distance between the center of the rim and the plane where the rim bolts to the hub (a measurement called wheel off-set). Because the new tires chosen will be slightly wider, we needed rims with a greater offset, so we ordered 7 new rims with a 5.35″ offset (the old rims had a 5.15″ offset).

The rims actually lived in our house for many months before we were ready to get the tires. Though they did finally get their tires attached.

And they finally made it onto the Turtle.

Some additional touches included new lug nuts all around, and lug nut covers. We could only find the covers in stainless steel, so we ordered them, had the 32 brand new covers powder coated black for $40, and installed them. They add a nice, finished look, and will keep the threads clean too!

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You can see we have a nice narrow tread but a taller traction tire. I did add a 1/4″ wheel spacer for the front tires to cancel out the additional offset of the rims and preserve (within 0.05″) the stock wheel center line for the steering. Luckily, the front hub was just proud enough to accommodate that and still have the hub-centric wheels centered properly.

The spacing between the rear tires actually increased slightly. All in all, it really worked out pretty great. The new tires will keep us safely stuck to the road in all kinds of weather and terrain, and I sure think they look pretty nice too! Maybe someday we’ll get even bigger tires…

Let’s Refurbish a Van – Part 2: Exterior Paint

Hello everyone! I hope your New Year has been off to a great start!

We’ve been spending much of our time lately getting ready to hit the road—we have just a little more than two weeks before we leave! While we’re as excited as can be to start the adventure, it’s also a bittersweet process as we fill up our social calendar to say our goodbyes. So for now I’m going to pretend I have plenty of time to discuss that aspect of the journey, and instead we’ll go into how we made a brown Turtle blue!

Shortly after we bought the Turtle, we began dreaming up plans for change. Right away, Andy was envisioning the rack and its sky boxes, beefy new bumper, and fancy new tires. For my part, I could hardly wait to cover it from top to toe in an exciting new color! So while Andy created scale model paper pieces of the roof and the racks he wanted to attach, we yelled out colors and mentally tried them on for size. The moment we imagined the Turtle in a bright Crayola blue, we were sold.

Just to get a reference point, we looked into having it done professionally. Needless to say, it was a lot. There is a lot of surface area on this vehicle! So Andy did some research (those words will be seen frequently on this blog) and decided our best bet was to buy some boat paint and do it ourselves. As we looked further into the process, we were really happy with the plan to use marine grade paint. Unlike car paint, we could paint it with a brush instead of a spray can or gun. And unlike other paints that could potentially be applied with a brush, it is made to be super durable in the elements. When Andy found a brand he liked, we looked at their color options and found, to my delight, the absolutely exact shade of blue I had been dreaming of! It was meant to be.

We sanded down the entire Turtle with wet/dry sandpaper, and primed it with white //ws-na.amazon-adsystem.com/widgets/q?ServiceVersion=20070822&OneJS=1&Operation=GetAdHtml&MarketPlace=US&source=ac&ref=qf_sp_asin_til&ad_type=product_link&tracking_id=blueturtlecro-20&marketplace=amazon&region=US&placement=B0017KKKDO&asins=B0017KKKDO&linkId=fc0af2f1af67f4d14ae20361bec4c6d2&show_border=false&link_opens_in_new_window=false&price_color=333333&title_color=0066c0&bg_color=ffffff“>Interlux Pre-Kote primer. The Interlux paints we used ran between $40 and $50 a quart, but compared to the cost of having the job done, it’s a great deal.

Then it was time for the serious business of painting an RV. Neither of us had any experience here, but thankfully Andy’s love of research saved the day again. The method most commonly used to paint boats is called “Rolling and Tipping.” One person uses a small roller to apply a thin layer of the top coat in small sections, then the other person follows behind and quickly but carefully uses a high quality brush to smooth out the bubbles. It’s important to make each section small in order to be able to blend it all together smoothly before the previous section dries.

For our project, we used a badger hair brush and //ws-na.amazon-adsystem.com/widgets/q?ServiceVersion=20070822&OneJS=1&Operation=GetAdHtml&MarketPlace=US&source=ac&ref=qf_sp_asin_til&ad_type=product_link&tracking_id=blueturtlecro-20&marketplace=amazon&region=US&placement=B001BWF718&asins=B001BWF718&linkId=d2af3fdcae720aa23812e2cc28f381b9&show_border=false&link_opens_in_new_window=false&price_color=333333&title_color=0066C0&bg_color=FFFFFF“>Interlux Brightside paint in Sapphire Blue.

Before we began painting, I was incredibly nervous that I would make mistakes and the Turtle would look like a bad kindergarten arts and crafts project. But as we neared completion of the three coats it required to cover the Turtle, I think we both gave up on the need for perfection, as it was astonishing enough that we were just two people and we were painting an RV! The paint goes on super smoothly, and it’s pretty incredible to watch as the brush glides over the bubbles and melts the texture into a glassy sheen. If you look closely at the surface, you can see light striations in the paint, but overall we are extraordinarily proud of ourselves! It took weeks to sand, prime, and paint three coats, but in the end we spent far less than we would have if we would have had it professionally done.

In addition to the blue, we painted the top of the Turtle with Interlux Brightside White, and the bottom with Rustoleum flat black. Though it adds visual interest, the primary reasons were practical. The white top will keep us cooler when the sun is beating down, and the black hides mud and dirt and camouflages hatch doors. We have small cans of all three colors on board, so if the Turtle gets scratched or dinged, we can easily mend it ourselves. We found that taping off the layers still resulted in leaks and a super uneven line, so I just used a small brush to freehand the transitions. So don’t look too closely there. 🙂

I’ll share some lessons we learned for those of you who are thinking of tackling a similar project. But first, some process photos!

It was a bunch of work, but our sense of ownership and accomplishment is a great payoff. Here are a few things we learned throughout the painting process:

It’s best to paint on a cool, overcast day. Otherwise, the paint dries quickly after rolling, and by the time you begin tipping it’s impossible to blend sections well.
We had better results when tipping if we lightly dipped the very end of the brush in mineral spirits.
It’s easier to blend the sections if you tip into the previous section.
Edge around windows first so you can move more quickly over the main surface. We started by edging as we went, and it made for a more frantic painting session.
Relax and be realistic. We wanted so badly for our very first vehicle paint job to be as perfect as those we saw in YouTube videos, but as we painted we realized that we’re beginners, and that’s OK. Sometimes bugs land on the paint. Sometimes the paint streaks a little. Sometimes you have to sneeze and the paint dries some while you look into the sun waiting for the sneeze, and then by the time you start tipping again the paint has dried a bit and it smudges, and then you dip the brush into mineral spirits to help it blend better, but you use too much and the now-wetter paint drips down the side and on to your shoes and driveway. After the job is done, those little details aren’t as glaring as they seem when your face is right up against the vehicle.

I’ll check with Andy to get his input about our learning process, and update the list. But that’s what I can think of so far. If we can do it, anyone can! And the results are amazingly satisfying.

Let’s Refurbish a Van – Part 1: Flooring

Well, it’s been raining virtually nonstop for the last few weeks in Portland, and Sauvie Island seems as if it’s ready to admit defeat and just merge with the Columbia River and call it a day. So I’m working from the island today, appreciating how warm and dry I am inside, and thinking about how just a year ago I was dreaming of this very scenario, feeling like the day would never come!

*Newly-formed lakes and sunken pumpkins on Sauvie Island not pictured. It has been raining so hard, one photo would send my phone right into a bag of rice.

These days, as we sit in the Turtle, eating dinner at the table or climbing up the ladder into our cozy lofted bed, we sometimes take for granted how much work actually went into this project. Because we gave ourselves such a tight deadline, we didn’t have time to stop and appreciate each accomplishment as it was crossed off the list, because there was another line item right below it requiring immediate attention. The moment we crossed one finish line, we’d look up and see there was another lap ahead of us!

A portion of the list.

If you’re thinking of taking on a similar project, or if you’re just curious how we got from Point A to Point B, here I’ll be discussing our process, and what we learned along the way. I will admit, our experience was made much easier due to Andy’s crazy number of useful skills! But if you’re like me and aren’t handy with welding, car mechanics, woodworking, and wiring lighting (among Andy’s many other contributions), don’t despair! The most inspiring thing about Andy is that when he comes across a job that requires skills he doesn’t have in his personal toolbox, he does research online, buys books, and reads the blogs of others who are skilled in that field. He then gets the needed tools for the job, and just gives it a go. Personally, I tend to get intimidated by new large-scale tasks that feel like they should require a professional. But throughout this project, following Andy’s lead, I found myself feeling empowered and excited to see what I could learn and accomplish. If I can fiberglass and epoxy a floor, anyone can!

The quality of this photo is terrible, but the cuteness is top shelf.

Our first goal in the refurbishment was to strip down the interior of everything we wanted to update. This included nearly all soft surfaces, as the Turtle is 30 years old and these tend to hold on to dirt and odor. . . and the design sensibilities of 1985.

So as it was the first change we made to the Turtle, for this portion of the blog, let’s discuss flooring.

This is one of the only photos we have of the carpet before Andy pulled it out – just a teeny slice visible in the bottom left corner. But you get the idea.

A bit more carpet shown here. We just got so excited to get started, we didn’t get a whole lot of “before” photos before things started changing!

First, Andy ripped out the carpets and the subsequent one million carpet staples. I’d like to say I’m exaggerating the number, but I kind of am not. I worked on just a 30″x30″ portion and the resulting blisters were highly impressive.

Underneath the carpet was the OSB flooring we were expecting to find. Due to its age and thickness, it tended to sag quite a bit when walked on, so Andy proposed reinforcing it with sheets of fiberglass cloth and epoxy. At this point, I’m going to use the pronoun “we” when I discuss our work on this project, because I now am a fully qualified epoxy applier, and proud of it! Though of course Andy did much of the up-front work before training me—but I felt very pleased with myself when I realized that I can now strengthen any old floor I like!

In a few areas, the flooring had rotted out pretty significantly. Ever the optimist, Andy was pleased that it was an easy early indicator of where we had leaks that we needed to fix, before finding out the hard way when the rain hit! So he cut out the soft blackened area and replaced it with another piece of OSB that he cut to fit.

So, in small increments, we 😉 laid sheets of fiberglass cloth over the floor of the turtle and rolled thin layers of epoxy over it with a small roller, eventually covering the full surface area and applying additional layers in the weaker spots. Between each layer, we sanded it down to keep it nice and smooth, as portions of the fiberglass tend to raise up a bit here and there.

Halfway epoxied. (Guess which half!)

It was so smooth and shiny that Andy originally wanted to leave it as it was. Truthfully, it really had a neat industrial quality to it, but as it was going to be our home, I was hoping for something a little warmer. He cared less than I did about this issue, so we agreed to find flooring to install over the OSB.

After researching a number of ideas for the flooring surface, we decided on vinyl stick-on tiles. They’re fairly durable, inexpensive, and if any damage is done to a portion of the floor, we can just pull it up and lay a new one in its place. Considering the fact that we plan to play hard while on our adventures, neither of us wants to tiptoe around the Turtle trying to keep it pristine. But we also don’t want to take all this time just to trash it either! So it seemed like the best route.

The majority of the options we found were square parquet-style tiles, which we liked, but I had my heart set on long planks. After some research, we found exactly what we were looking for at Lowes: cherry “wood” planks with some textured striations to give it a more realistic wood feel. They sell them both by the box as well as individually, and are relatively easy to cut to size.

Aside from the fact that the Turtle has some ca-raaazy angles, installation was fairly painless. I’d imagine if you have a more uniform and rectangular vehicle, you’d have an easier time than we did. The Turtle, though, is made up of friendly-looking but unpredictable curves and turns, so both we and the box cutter were put to the test.

But we got it done, and there you have it! Brand new floors. They’ve been holding up great, and with all the rain and mud we’re experiencing out here lately, I’m so appreciating the ease of hard surfaces as opposed to a muddy carpet to clean! And with the recent addition of a few navy runners, it really feels like home.

The Turtle “After”

So now is the point where we get to show the result of a year of hard work on our tiny home! I’m typing this while drinking coffee at the table and listening to the rain on the roof while keeping nice and warm inside the Turtle. Looking back at the “before” photos, it feels a little unbelievable! This crazy old van is now our cozy home.

I was going to post side-by-side “before and after” photos today, but realized that since I took the “after” photos on a grey and rainy afternoon, the impact doesn’t do it justice, as the “before” pictures were taken on a bright sunny day! So that post is on the horizon.

Here we are!

It kind of feels like a boat. I like that.

Kitchen and Dining Room

Bunk beds!

Love the Tardis painting by my talented brother-in-law David

Andy cut down and refinished an old desk he’s had for years to make the table

We love the no-spill bowls for the pets

Andy picked this fabric! We promise not to over-do the turtle references, but it was super cute and coordinated nicely with the other prints

Maximizing the limited closet space

Nothing we own can be larger than 10″H x 9″D

I love the wood Andy installed next to the new upholstery pattern.

And there we have it! I’ll post more pictures soon!

The Turtle “Before”

So let me catch you all up on where we began, and how far we’ve come in this last year in getting the Turtle ready to go! A lot of work has gone into it already, and with a little over a month before we hit the road, we still have plenty to do.

We bought the Turtle from a couple who were the original owners, and who had taken such good care of it over the years. But while it was in great shape, we wanted to update and customize it, making it our own little home.

We weren’t super great about taking photos initially, because it was so far from where we wanted it to be that it didn’t occur to us that we’d want “Before” photos! And I don’t think we have any of it with carpet, since Andy was such a go-getter that he ripped it out almost immediately. You’ll have to use your imagination there. 🙂

So here’s where it began.

Minutes after buying the Turtle!

The loft

The bathroom

So. Much. Brown.

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