RV Conversion Part 2 and Trial-Out

A month has gone by since my first update on the RV conversion. I am happy to report to get close to the finish line, but here is a more detailed update. Progress was much slower than during the first month. I guess the first rush of excitement faded to the realization this project is more w**k than I anticipated. Also, lacking a good work surface in the garage, I used the floor and the constant up and down and kneeling on the floor took its toll and I started to have pretty bad pain in my right knee which also did not help with my running. I realized I had to slow down and I gave myself a mandatory five day PTO.

Phase 1: Floor & insulation

Status: Still 90% done

I still need to put down the vinyl flooring (Phase 6) and install the RV table. The 2'x2' table top came in from Amazon, but it is way too heavy! I think I will just use regular 1/2" plywood for this. As I now have a good table/countertop in the back cabinet I will put this on the back burner for now.

Phase 2: Electric & Appliances

Status: done

This month I finished installing the second solar panel, the 110V distribution and the additional LED ceiling lights. The lights can be turned on and dimmed from either the right side entry door or from the very back in case the hatchback is opened. I have to admit the position of the first light was predetermined as I ruined the ceiling liner when I drilled through the roof for the two solar power cables. This is now the position of the middle left light.

I also procured a second smaller inductive stove top for coffee in the morning and as second burner when cooking. It is only 500W compared to the first 1,500W unit. The inverter should be big enough to power both in parallel.

2nd panel installed (200W total). Waiting for son to wake up to help me lift this back onto vehicle.

Hopefully last time I had to lower ceiling liner to install wiring for LED lights. You can see silver Reflectix insulation I added in addition to the 1/2" insulation of the ceiling liner. Notice the black cables coming through roof from solar panels and green curtain airbag on passenger side.

Six new LED lights. The original ones powered from the starter battery remain as is.

Phase 3: Bed

Status: 95% completed

I built the storage drawer underneath half the bed as well as the "door" in-front of the other half to prevent stuff sliding out. I have not started widening the bed with optional plywood, but I have bought the 3" foam for that side. Need to find someone with a sewing machine to make a cover.

Phase 4: Side cabinetry

Status: done

The AC now rolls out nicely through the side window to the outside. I have to admit there was a lot of luck involved to make this work. Once outside foam padding is inserted to seal the inside from the outside. I also completed all cabinetry doors and installed bungee cord at the very top to hold some loose items, like paper towels, beer cans, TP.

AC unit "deployed" through open window. The slope is intentional to prevent condensate running back into the RV.

Completed side cabinet with roll-out AC (here retracted) and microwave. Top shelf proved to be useful for paper towels, TP and beer cans.

Phase 5: Back cabinetry

Status: 90% complete

This is where I made most progress on. The back cabinet hold the fresh and gray water canisters, sink, faucet, water pump and countertop. Also, in case the hatchback is open the additional countertop can swing up so I can cook outside. Left to complete is to finalize what else is between back and side cabinets underneath the countertop.

Mock-up of sink and 6 gal fresh water canister. Smaller 2.5 gal gray water tank will be below sink.

I have running water!

Outside cooking! Also, on bottom right opened new drawer under bed.

Current progress with completed side and rear cabinets. Not sure yet what to add underneath white drawer below countertop. Maybe nothing? Also, notice fruit "hammock" above countertop.

Phase 6: Vinyl Floor, Painting, Final Trim

Status: 0% completed

This phase has been officially postponed to October or later. Firstly, it will require complete disassembly and reassembly of everything to install the vinyl floor. Secondly, I don't want to paint anything until I am sure it is complete and working as intended. So I need a few actual camping trips. Lastly, I want to wait for this heat to end.

Lake Lure Camping Trip

With the RV in its current state I joined the Raleigh Trail Runners (RTR) on a trip out to Lake Lure. However, instead of leaving Friday I decided to already leave Thursday and spend one extra night at Pilot Mountain SP, where I have not been since before the big fire in December 2021. I would then meet up with the rest of the group who rented an AirBNB Friday afternoon and use the camper there until I leave Sunday. So overall I spend three nights in the camper. Here some key takeaways and below some pictures of the trip.

RV Pros:

Fully packed, the vehicle still got an average of 29 mpg over this 500 mile trip. Not bad! Also, I was pleased to not hear too much annoying rattling from the setup.
There is definitely sufficient storage space for a long trip.
Bed works fine for me. The 25" width is not too narrow and the length with the passenger seat in the most forward position is more than enough. I'd guess 6'5", although the mattress itself is only 6' long.
I did not use the AC as it was cold enough with windows open (I have bug screens) and a small 6" fan running. I will camp again this Friday at Raven Rock SP and I assume the AC will have to be used then.
Cooking worked great with countertop stove top, although I missed my gas grill which I did not bring. Also, the microwave proved to be very useful.
There was also sufficient water. I did not refill the 6 gal canister during this 4 day trip. However, I did not cook two nights.

RV Cons:

Although there is no rattling driving the AC unit contains two styrofoam pieces that lay on top of each other. These do occasionally squeak, especially driving on poor roads.
The new LED lights are very bright (good), but too bright at night. When turned on they always go to the brightest setting instead of the last used and it takes a few seconds to dim down. This is somewhat annoying.
The water pump seems to be excessively loud. It is a diaphragm pump. Not sure what I can do about that. Maybe put some insulation around it?