Sprinter 4×4 Camper Van Build: Day 5.

When considering building out our own van, some of the more intimating items included running propane, installing windows and using spray foam. Today we get to check one of those items off of our to do list: spray foam.

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We ended up using the Great Stuff Gaps and Cracks expanding foam. We thought it would be better for this build than the Big Crack Filler. And it was but in hindsight we should have used the Great Stuff Door and Window because it doesn’t expand as much.

Sprinter 4x4 van build day 5 day50411218

Our one can of the foam wasn’t nearly enough so we ran to Lowe’s to pick up another two cans. Somehow we got distracted by the Costco across street and their cheap hot dogs and we ended up leaving with a a couple boxes of beers and shoes. You got us once again, Costco!

Sprinter 4x4 van build day 5 day50411218

Before we reattach the headliner and add walls, we have to run all the pre-wire. For any lights, electrical outlets, solar, etc.

Sprinter 4x4 van build day 5 day50411218

I’m not much for electrical work so I’m glad Dan understands what he’s doing.

Sprinter 4x4 van build day 5 day50411218

I’ll just sit here and keep measuring and cutting this foam board. I can’t wait for this crap to be done.

Sprinter 4x4 van build day 5 day50411218

One of the reasons for our fear of spray foam came true for us today. Dan went outside to check on the outer skin of the van and noticed a faint crinkle. He wasn’t sure if it was real or in his head so he gently pushed on it. And guess what? He crinkled the outer skin of the van WITH HIS HAND. What the F. I’ve heard that the skin of the Sprinters are thin but was not expecting this. We spent the next couple hours staring at it and feeling like crap. It’s not really too noticeable but we know it’s there. Sucks.

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The FedEx guy came by the house and distracted us with our new 6 volt batteries.

Sprinter 4x4 van build day 5 day50411218

A lot of people slip their batteries under the Sprinter’s passenger seat.

Sprinter 4x4 van build day 5 day50411218

It seems like an ideal place for the batteries but access to them is kind of a pain in the bottom. You would have to physically remove the seat from the chair base to get to the batteries every time you want to check on them. Dan is thinking that mounting them near the bench seat would work better for us and easier for running wires.

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The kids all came out today to help with some measuring and cutting… and posing in the sunshine.

Sprinter 4x4 van build day 5 day50411218

The skin warping happened near that wheelwell on the bottom right hand corner of this photo. We removed the foam board to see what happened on the inside and there is no spray foam in that area. So weird. It freaked us out enough to get us to chip away at some of the spray foam later that night.

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Nothing to do but to be more gentle with the foam tomorrow.

Sprinter 4x4 van build day 5 day50411218

I’m soooooooo ready for insulation to be done. So ready!

Sprinter 4x4 van build day 5 day50411218

Here is the video Dan put together on YouTube. Enjoy!

See you tomorrow,
Marlene

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