Custom-Made Comfort for the Road

A modified Ford T-250 was the perfect platform to create a functional, trustworthy RV for a return trip to Alaska.

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Words by Wes Kirk

Imagine a trip consisting of dirt roads strewn with pot holes and copious amounts of dust on some days and unforgiving mud on others. Now, imagine 900 km (560 mi) of these conditions.

The Dempster and Inuvik–Tuktoyaktuk highways lead all the way to the Arctic Ocean amongst the vast tundra, which spreads for miles with minimal vegetation in sight and only a towering pingo standing proud in the distance.

To say the scenery along these stretch of roads is breathtaking is an understatement. “Life changing” might be a close description, but it still doesn’t quite capture what I experienced on this trip. However, there was a whole other journey just prior to this trip, which entailed all the preparation to spend weeks on the road.

To be a little more specific, my plans entailed purchasing a transit van, and then re-designing and building the interior with many creature comforts (including solar power) for a much isolated and comfortable experience from home. There’s much to talk about. So, let’s get started.

I must confess that the only part of this van that doesn’t fall under “budget build” is the van itself. I actually purchased a brand new Ford T-250 transit van, which was strange considering my previous vehicles have been Toyota 4x4s, a Mitsubishi Pajero, three Volvo station wagons, and a 1980 Dodge camper van. Everything except the Mitsubishi was under $2,000. So, buying brand new was a whole new and enlightening experience.

My reasons for purchasing a brand new van was because I had been doing the “van life” long enough that I could easily justify the purchase. Plus, with my longer trip on the horizon, I wanted a trustworthy and dependable vehicle. As a Red Seal Certified Automotive Technician, I know older vehicles can be trustworthy, but I wanted a blank canvas for this masterpiece.

In fact, it was so blank that it came with a mere 6 km (4 mi) on the clock and the only people I could blame for reliability issues was Ford itself (and not the poor maintenance of previous owners).

My build list for the 2019 Transit T-250 included:

  • 3.7 L V6 engine
  • 6 Speed Automatic
  • 4.10 rear differential
  • Blank interior

The van was so baseline basic that the only option I selected was the windows in the sliding door, the rear barn doors, and the colour. Simply put – basic means easy to fix with less stuff to break. I also wanted the interior to be basic but very functional – all in a light weight design (just think a backpacker’s version of a van interior).

Starting with warmth, I installed Rockwool batten insulation where I needed to cover a lot of space, hardboard for thinner areas, and spray foam for the tighter spaces. I then covered the walls with 1/8” plywood sheets. I then moved created the more functional space of my van. I installed a kitchenette that was simply a counter and a small cabinet with a Wallas diesel stove heater for cooking and heating. I also added a small one-burner camp stove for cooking outside.

As I didn’t want to have a permanent sink, which would only take up precious counter and storage space, I added a bin for washing dishes (and other purposes) with water provided

by placing a jug on the top of the cabinet (a more efficient design for accessible water is in the works). The only real kitchen appliance was a Dometic fridge, which can run 24/7 and has never let me down (aside from user error).  

I passed on installing a compact bath/shower combo for weight savings. However, a Dometic chemical toilet has a home neatly under the bed. Plus, for refreshing showers, I generally stop in at a gym or community center. Truthfully, with the van’s short wheelbase and limited overall height, there just wasn’t the ideal space.

To finish the interior, I still needed to determine a few things. I required a bed, an area to organize my clothes and space to fit my motorcycle. This meant I had to put the kitchen on one side of the interior with the bed on the other. So, I built a folding slatted bed frame with slats spaced 1/16” inch apart. Every other slat is attached to the bed frame, while the remainder is attached to the side that slides out. Folded out, it’s almost a queen size bed and has a 3” foam mattress. In fact, when the bed and mattress are folded up it creates a comfortable couch. My design also resulted in plenty of storage underneath and my dog even has his den under there, providing a comfortable space to sleep.

While I was “Habitat for Humanity” one day, there was an old well-built dresser for just $80.

So, I purchased it and found it fit perfectly in place. It was such a simple, effective solution. I also painted it to match the rest of the interior. While it is a basic interior, it’s very functional as I had originally planned. Plus, with the bed folded up, I had the space to fit my motorcycle! So, with my time of departure fast approaching, the van was finished and ready to go.

Without even doing a pre-trip to iron out all the bugs, I picked up my best friend and we drove north up Vancouver Island to Port Hardy, and then caught the ferry to Prince Rupert. We then traveled to The Stewart – Cassiar Highway, where we enjoyed a mix of sealed roads and roads under construction, until we reached The Alaska Highway. Once in Whitehorse, YT, we took the Klondike Highway and made our way up to the start of the Dempster. Realizing the unpredictable nature, we were prepared with extra fuel, good tires, a spare tire, and lots of food.

My parents were also along on for the journey in their 1990 Dodge Islander. I would argue that those old Islanders have to be one of the best camper vans ever built and was stupendous the whole way. Without a gas station in sight, I enjoyed the 20 mpg I was getting with the Transit Van. It amazes me how well these new vans run. I have to admit though, when it comes to comparing my dad’s camper van to mine, his Islander has a wider fiberglass body, which allows a more functional interior space.

In the end, however, the trip was a life changing experience and I can’t wait to get back on the road. Before then, however, my plans include building a ladder for the rear door as well as a spare tire rack and storage box for the other door. I am also adding roof racks, a small leveling kit, and a skid plate for some added protection to the front bumper.

As some we’re inquiring about the overall cost, I’m happy to say the total came in under $4,000, which is what I had budgeted for. Even though it was a basic build that turned out to be very effective and comfortable, if you are planning on re-building a van to your specs and preferences, all I can say is do it! I’ve done a couple of them and the experience has been amazing both times.