refurbishment

RTR: Our First Van Meetup!

I was writing a blog post in Yucca Valley, California a few months ago as part of our boring-but-more-fun-when-in-the-sun errands list mentioned in the previous post. At that point, our plan was to visit Slab City, NOT get stuck in any sand, and then head down to the Mexicali border and over into the Baja.

But as usual, our plans were no match for Greater Travel Forces.

Andy decided to use my blogging time to make a Home Depot run—don’t worry, he did ask if I would feel left out if he went alone, but I said I’d just go on tomorrow’s Home Depot run and skip this one.

While he stood on top of the Turtle in the Home Depot parking lot, a group of guys came over to find out what in the world the Turtle was, and asked if Andy was on his way to the Rubber Tramp Rendezvous. He was as confused as you may be right now at the perplexing name, but he asked for further information, and when he rejoined me at the coffee shop he had this information to share:

Rubber Tramp Rendezvous—or RTR for those in the know—is a yearly meet-up for vandwellers, RVers, and road travelers of all kinds held in Quartzite, Arizona out on a huge acreage of BLM land just outside of town. It’s been going on for seven years, and each year the attendance grows exponentially. The guy who organizes it has written books and has a popular YouTube channel aimed at helping people live the full-time van life. For the two week duration of the event he puts together a schedule of seminars, and people who specialize in certain aspects of van building, traveling, solar, or living in small spaces, for example, hold informal outdoor conversations about their area of expertise and answer questions. It’s also a place where a whole bunch of travelers come together to talk travel and give tours of their vans.

We decided instantly that we needed to go check this thing out.

After making our way out of the Slab City quicksand, we took the 2-hour detour east to Arizona and added the Turtle to the group of about 4,000 vehicles scattered around the desert in semi-organized clusters. We thought that before we tried find a place to park we should find the main camp so that we’d have a general sense of the lay of the land. We drove past countless vehicles and signs pointing down dirt roads for various sub-groups meeting one another until we saw a tiny yellow arrow pointing to the right that said “RTR”. We drove in, but the path directly to the main camp was lost among the braided roads created by the vans and RVs, so we just started driving, asking directions, and trying again.

Everyone looked like they were having such a great time, chatting with one another, setting up chairs in small circles, sharing food, riding bikes, and playing music. There were people of every imaginable walk of life and ages ranging from early 20’s to octogenarians. We kept driving and guessing at our route until we reached a dead end at a cul-de-sac created by a circle of vehicles around a huge campfire ring and a sign in front that said “Camp Slow Dust.” A cheerful group of people sat around a table and waved at us as we passed. We stopped and asked them where we’d gone wrong in our search for the main camp, and they pointed to the next path over but said not to bother; we could just camp with them!

We thought that sounded great and backed into a spot around the perimeter of the camp. (Photos below were taken on our last day when almost everyone had left. I’m not sure how I failed to take better camp photos. Living in the moment, I guess.)

Most of the group had met each other at a van build about a year ago and have been traveling together or meeting up periodically on the road with one another ever since. They were all so much fun, and Andy and I kept saying how happy we were to have landed in that camp. We’d originally thought we’d stay for a day or two, and ended up having so much fun that we stayed until the end of RTR six days later!

The beauty of meeting people in the context of a van meet-up is that no explanation is necessary regarding each person’s individual lifestyle rhythms. Everyone comes and goes as they please, spending time in small groups, sometimes the small groups becoming large groups, taking walks, taking naps, fixing vans, helping others fix vans, sitting outside to read, giving van tours, and on and on. It’s like summer camp.

During our stay with Camp Slow Dust we became friends with Wayne, Jeff, Cheryl, Gio, Greg, Jordan, Boom, Victor and Winter. Every night Wayne and Cheryl made a big family dinner for the camp, utilizing contributions from the group to add to the meal. We’d all sit around the fire on benches the guys made from huge planks they brought in, and as the week progressed the benches got shorter as the wood was tossed into the campfire.

On any given day you could find Andy next to someone’s van, so blissed out by the availability of people who wanted to talk about solar, wiring, engines, ProFlex, stainless steel hardware, tires . . . and everyone there loved to talk shop as much as we do. It was a lot of fun swapping ideas, and everyone there had a project going on. Greg has a Ford van just like the Turtle, but minus the shell, and after he and Andy had been chatting for a bit, Greg went to town and picked up a couple of cake pans just as Andy had done earlier this year. Soon his van looked like this:

On any given day you would find me enjoying standing in the sun and chatting up new friends in the camp while I threw the frisbee for Scout. I thought I’d go see more seminars and wander the desert more often, but all the fun seemed to happen in the small loop of Camp Slow Dust.

There was always something fun going down right outside our door!

I helped Wayne and Victor install power locks in Wayne’s van. (Wait, I was going to take full credit for that job. Oh well.) I loved hanging out with Wayne, who cares so much for the people in his tribe and welcomed everyone passing Camp Slow Dust to join us at the fire and share food, drinks, and stories. He leaves no one behind. We’ll definitely be meeting up with him down the road.

I also got to babysit Wayne’s little kittens, which was a position I was highly qualified for.

I spent a bunch of time chatting with Cheryl and mining her knowledge of plants and herbs and cooking on the road. That woman is a treasure trove of ideas! She wastes nothing, and one of my favorite tips is to cut up the green carrot tops to add to salads or dry for seasonings. They taste just like carrots and are good for you too. Cheryl gave us a tour of the main camp right when we arrived which made us feel very welcomed, and another day she walked me out to see the labyrinth someone had made.

We drove into town with Winter and wandered around the bustling town of Quartzite, admiring the myriad piles of rocks and minerals for sale under all the tents, as well as the weirdest/best grocery market.

Everyone at Camp Slow Dust made us feel so welcome and we were so happy we turned onto the wrong road on the way in. RTR was our first van meet-up, and it was eye-opening to see how many fellow travelers we’re surrounded by as we move around the continent.

Andy and Jordan talked extensively about solar, which was to come up later in our travels. In the meantime, you can start getting to know Jordan better through his charming and hilarious documentation of his travels from Seattle to the southern tip of South America.

Untitled Travel Project

I daily admired Greg’s lovely rock balancing and natural sculptures, which I’m told he does to beautify every campsite he stays in. He’s a world traveler full of love, and he has a YouTube channel and Instagram account documenting his travels, which you can follow here:

Yogi Van Life: YouTube

Yogi Van Life: Instagram

Jeff took Andy and I out for a ride in his side car, and he even got to ride in his own side car for the first time. Of course he made it look way cooler than we did.

On the last night of RTR, they had a campfire at main camp and a little ritual they call Burning Van. Afterwards, we had our own, much more impressive, sendoff—The Burning of the Benches!

Gio and I made sure the kittens weren’t left out of the fun.

When we turned in for the evening, Andy made sure Gracie got her fair share of snuggles too. I love these little buddies.

What a week. It was our first van meetup, and will definitely not be the last. We both felt so at home among the thousands of other travelers, surrounded by likeminded people who understand us and why we’ve chosen this crazy lifestyle. And just like summer camp, we said our goodbyes knowing that in one short year we’ll all be back sharing new stories around the Camp Slow Dust fire again.

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!!!

A Month-Long Detour: Oklahoma City, OK

In our last post, I alluded to a detour we were embarking upon to visit some friends in OKC. I couldn’t have imagined that when I finally had time to write about it, we’d have also moved the party to Texas and extended the trip by two weeks! But with old friends, it’s hard not to want the good times to keep rolling, and by the end of it both Beth and I were convinced that we’d talked the other into prolonging the fun. So it was a win-win.

A quick history: Beth and I were randomly-assigned roommates our freshman year of college at University of Montana in Missoula. Because all of our pictures are in storage right now, the best I can give you is this little gem that I found slipped between the pages of a sketch book while organizing the Turtle one day. Please note the high-res quality of a photo taken on a first generation web cam and printed on a 90’s era printer. Also, that we were as cheesy then as we are now.

After moving into that tiny shoebox together, Beth and I gradually became friends, cracked each other up, invented games, stayed up until the sun came up, moved to Juneau, and caused some trouble together in the years to follow. Now, just a few short years later (Right? That’s what it’s been, right?) we still see each other every year, but still that’s not enough. So when Beth pointed out to me that we were only 7 hours from Oklahoma City, much closer than I’d realized, we put a pin in the New Mexico plans and turned that steering wheel east to go hang out with her and her family for a week or two.

Needless to say, we had all the fun. Unfortunately Beth and Johnny still had to do real life in the meantime, so we hung out with them while we could and then explored the city on our own while they worked.

Highlights of the trip included:

The Thunder game! They were playing the Portland Trailblazers, coincidentally. So after living over a decade in Portland, I saw my second Blazers game in OKC. I’m a baseball fan, all right? 😉

The Horse Thief show at the newly-renovated and super-cool Tower Theater.

Taking Scout to the field near their house to play frisbee in the middle of the city.

Taking our picture in front of the wall of their building, which Beth says everybody does, so we had to do it too. We like to fit in with the locals. 🙂

Playing with Asher, then continuing to play with his toys long after he lost interest.

Beth’s top-tier crown-making skills.

Going to the Oklahoma City bombing memorial and museum. (If you’re in town, GO to this remarkably well-curated museum, but be prepared to be emotionally fried afterward. It was extremely moving and we were spent by the time we left.)

Exploring Brick Town, Deep Deuce, Midtown, the Plaza District, and Automobile Alley on our bikes. Again, we like to feel like locals so I’m showing off our OKC knowledge here.

Riding our bikes by the baseball field and seeing that there was a free high school baseball game going on! We’d admired the stadium from outside a few days prior, so we were thrilled to get to see it inside.

Taking a walking tour of all of Beth and Johnny’s favorite spots with their friends Mike and Sandy (taking the pictures).

Watching Andy reach peak stress levels playing PacMan.

This.

We had SO MUCH FUN. Beth and Johnny were great hosts, and great sports. 🙂 Oklahoma City has changed a lot since the last time I visited about 5 years ago. We were going nonstop and still didn’t see everything!

One weekend, we decided to go camping at a wildlife refuge a few hours outside of town. We saw bison and wild turkeys.

Scout and Gracie had to be leashed, but were just happy to be outside smelling all those great animal smells.

Gracie’s a pro at tangling that leash up.

One day it was so windy that we drove into a little town nearby to go get huge hamburgers at a place that Beth and Johnny often frequent when they’re in the area, and still don’t know whether they love the spot or despise it. On this trip, we all agreed it was awesome, but we could also see that it had the potential to swing wildly from charming to exasperating.

Beth and I attempted a Boxcar Children photo.

Here is Asher’s recreation of the trip, including the Turtle, him in his tent, the fire, and the lines on the top left show the howling of the coyotes we heard in the distance. It’s perfect.

When our planned two weeks were up, we still weren’t ready to stop having fun. So we decided to get a week’s head start on Beth and Johnny while they worked through the week, and then we’d all meet up at Lake Meredith, north of Amarillo. It’s a free NPS site with lots of fishing, boat and swimming access, plus spectacular views of the lake from the camp sites perched on top of the cliffs.

The first night, Andy and I stayed on the Cedar Canyon beach.

The next day, we scouted out the myriad sites surrounding the lake. Many of them have bathrooms, potable water, and even hot clean showers. We still can’t believe this place is free! It’s better maintained than some sites where we’ve paid to stay.

We decided on a site at the Sanford-Yake campground.

Because we had no neighbors and the sites were so far apart, the animals got some freedom. Scout still loves his stuffed worm, so thank you again Eric and Willow! 🙂

Beth and Johnny arrived a few days later, and we continued the fun! We had a few gorgeous days and a few windy/chilly days.

There aren’t enough superlatives to express how much fun it was to spend so much time with Beth and her family, for the boys to get to know each other better, and to create new memories and inside jokes like we did in the old days.

After they left, I sat by the fire for a little bit and tried not to mourn too hard.

We went back down to the beach to lift our spirits, and the weather was so perfect we both got a little bit tan. Scout swam while Gracie watched Scout swim, perplexed.

We had another fire that evening and cooked up some hot dogs, knowing that the forecast was going to change drastically the next day!

Aaaaaaaaand, it did. We woke up to blasting wind rocking the Turtle and rain pounding the roof. When I opened the door to let Scout out, he jumped down into a river rushing under us!

After all the fun we had over the last month, we decided that we were ok with a stormy day and that it would actually be quite cozy to cuddle up in the turtle, have some coffee, read some books, write this post. . .

But first, we had to take advantage of the rainfall and give the Turtle a bath! (When you live on the road, you’ve got to take advantage of opportunities when they arise.)

Let’s Refurbish a Van – Part 6: Roof Rack (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.}

So, we have stuff to carry. And we want a place to store our solar panels. And we want to stay cool. And, if possible, look cool. So, we need to put together a roof rack…

Here are a few pictures of the old RV when we got it. It had an aluminum ladder that was old and worn, along with the typical RV aluminum tube luggage rack at the back- all bits with some of the mounts loose. We also had a big plastic storage box bolted to the top, but it was cracked and would certainly leak. As you can see, there was also one solar panel and a mount for what I’m pretty sure was a TV antenna. Good stuff, but it was all pretty worn, as it had all traveled for close to 30 years and more than 250 thousand miles.

We wanted our rack and top equipment to do a few things for us:

Have a dry and accessible place to store camping and fishing and other fun gear, out-of-season clothing, and some spare parts and equipment.
Have the rack removable, so we can maintain and fix the roof when the need arises.
Have a location to mount the planned solar panels.
Design the rack to provide us shade.
Have a system that we can change, add more solar to, move things around, etc.
Be able to fill and seal up all the holes prior people made when mounting things to the roof, and have a system where moving forward we will not be drilling into the roof any more.

Anyway, roof racks look great! I hear they can be useful too. In truth, we have pretty limited room and storage inside, so having a bit of room up top for our extra supplies and garage-like stuff was essential for a successful voyage.

$safari-van-roofrack-back-retro-roof-rack-cartoon-style-isolated-white-view-61268999$

So, to the step of getting the old stuff off and sealing up the holes. Pretty much unbolt the bolts and pry everything else off. I then used fiberglass impregnated epoxy body filler for all the big holes (I love epoxy!), maybe adding wire to support it as it cured. I then added Geocel Proflex on the seams. I read about and tried a few things, but to date, it is my go-to for exterior sealing. Here is a link.

For the (many) smaller holes, I would first clean and fill with the Geocel, then screw in a stainless steel screw the size of the hole, then cover the head of the screw with another layer of Geocel. It is a technique I read about on the internet, and it seems to have worked well so far. Again, it is not worth buying any hardware but stainless or grade 8. It does cost a little bit more, but use the savings you get for doing this yourself to get the good hardware. Plus, you don’t have to worry about some interior rust and redoing the work down the road. After sealing the holes, I put down Rustoleum on all the modified spots. The following pictures show the antenna hole through the roof, and some of the removed parts scattered in the yard.

We were lucky enough to have a friend who worked for Yakima who gave us a VIP discount card for one purchase. With the card, we got 12 A1 rain gutter towers, 6 78″ crossbars, 12 wide body rain gutters, end caps, two 12-peice lock core sets, a Loadwarrior basket, and some cargo nets. A truly impressive amount of wonderful Yakima pieces at a great savings. Boxes and boxes of sweet components!

From REI, Amy and I used our one-item 20% member discount and each of us bought a Skybox Pro 12, shipped to the Portland REI for free. We got the long and narrow boxes to configure end-to-end, and not take up too much roof area width-wise. We effectively have the roof racks for 4 vehicles, all to put up top the Turtle. It added up to a lot of initial investment, but it has been working well, and added an important comfort to be able to store a reasonable amount of things to make our small world flexible, and I think it actually has a sleeker look being made from components—as opposed to a custom-fitted rack. Since we were doing all the work ourselves, we decided to invest a bit more on some nice new hardware. After popping down to REI and loading our new Skyboxes (in their own boxes) onto the top of the old Scout, we stopped for a bite in downtown Portland. Seems fairly reasonable to me, but I imagine to some people we made a sight…

The sky boxes, along with the other hardware, sat in the house for quite awhile. After stripping and sealing the roof, it was only logical to finish painting the Tutle blue, then do the white roof paint, and then finally get to the point where we could install the new roof rack. Consequently, this is what our place looked like for quite an amount of time. (As you can see, our front room was used to store a number of Turtle parts until they were ready to install.)

The pictures are few here, but after most of the painting was finished, I mounted the wide body mounts. I measured, marked, measured again, checked, and had the geometry figured out. On the corner of the Turtle roof, I would drill my two holes, fill with Geocel, cover the mounting surface with Geocel, align the bracket, screw in two (you guessed it) stainless steel lag bolts, then cover the seam and outside with Geocel. After it all cured, we repainted with the Interlux. It looked nicer with the black brackets and shinny bolts before the sealant and paint, but I didn’t want to risk it. And, just so you know, the asymmetric spacing along the length of the roof is due to needing to align the crossbars so they will not interfere with a roof vent when open, but also allow for the mounting points of the skyboxes. Here are the brackets installed:

It is a nice feeling to know that at any point we could unlock (all keyed alike, now) the 12 towers, unscrew, and remove the whole rack if we had to do some maintainence on the topside. Anyway, the pictures are limited at this point, but following are some involving the tower, crossbar, and rack install.

You might notice that the Yakima basket lost out to the solar panels. The basket is in the storage unit presently, and it would be great to get it up there at some point. When we were building and installing the rack, though, the geometric logistics were far too difficult for the time allocated. Anyway, to install the solar panels, I bolted two pieces of 12′ 6061 T6 aluminum square tubing to the crossbars with stainless steel carriage bolts and nuts fitted through the Yakima Universal Snaparounds.

I picked up used ones super cheap here. By the way, ReRack in Portland are nice people and can save you some money on roof racks, so check them out if you are in the area. Back to topic, after getting the aluminum properly spaced and installed, I then drilled and screwed the solar panel brackets to the the aluminum. That step was a breeze. Solar panels installed, photo taken probably a month in.

As to keeping it all cool. We planned on (and did), paint the roof surface with a couple of coats of Interlux topsides white boat paint. We actually painted the roof vent covers white as well. The assumption is that paint will reflect much of the sun’s heat, and be able to withstand the UV rays. So far, everything looks pretty good up there. We have some cracks in the paint where the caulking we used was not completely cured before we painted (I don’t blame the paint, we had time constraints), so we have some washing and fixing of some seams to do. Otherwise, all looks pretty good. A common approach for keeping a bit cooler is to have a couple of roofs, effectively carrying your own shade along with you.

The above old-school Rovers have a second roof with an airgap for passive cooling in the hot sun. (Side note, did anyone notice the tall skinny tyres the rovers are running on?) With the spacing added from the rack towers, and mounting the solar panels and boxes above the crossbars, we have a impressive air gap and continous shade on over 50% of the roof.

Currently, there is a middle strip free for walking, in which I will fit an additional panel at some point, then simply make some cheap synthetic or plywood panels and paint them white to increase our shade to close to 100%. So far, though, we have been to the Badlands of South Dakota in the summer, and have stayed with the ambient temperature with thoughtful venting and minimal electric fans.

To me, the goal is not to be cooler than the outside, all we need to do is not be hotter than the ambient temperature in all kinds of weather.

Oh, almost forgot, we want to access the roof! We need to clean the solar panels, get stuff into and take stuff out of the boxes, check on all the paint and seals, and most importantly, be able to climb up and yell with arms outstretched like you are in a movie! Anyway, the ladder…

We actually bought a car roof rack ladder as a start. The almost $200 ladder (seems crazy) was well worth the money, in the time saved. It always feels pretty weird to buy something new, remove it from the box, then start cutting it right away. So, the ladder, welding, adding more rungs for the proper length, and fixing the folding function.

Some close-to-final pictures here. We started with a 9-rung foldable ladder, and ended with a 12-rung rigid ladder that bolts to the bumper and the top rack. Again, it was designed to bolt to the bumper and rack, so it is removable…

I’m pleased with the removability of the ladder, because we crushed it a bit when we backed into a tree one day, about a week after it was finished and installed. The ladder was subsequently unbolted, straightened, and remounted. From the side, it now does have a bit of ripple (below the designed joint and by the spare tire)—this is what we call life.

To sum up a bit, up in the boxes right now we have a few fishing poles, extra wire and parts and unfinished projects, cloth for sewing projects, extra window insulation, snow shoes and masks and fins, river tubes, my old tent. A pair of driving lights I have yet to wire up. Some cheap speakers I plan on installing in the doors. You get the picture. We call it our attic.

We have a completed rack now. It holds our solar panels, is our attic, and still has room to exapand.

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!

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!

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