Van Plan

[MattWallace]

Hi all, first post. Time to introduce my van.

I have a 97 Econoline Supervan that I bought new (actually ordered it) and now has around 67 000 miles. The OEM batteries conked out this spring, and the vacuum pump croaked at about 62 000 miles. Other than that, it has been stone ax reliable, although the Service Engine Soon light has been coming on. I couldn't stomach paying the $70 that I was being quoted to pull the code, so I bought an AutoTap to do it myself. The light is being driven by "low voltage glow plug bank" or something like that. I have read about flaky relays, so I bought one, but don't have the service manual (more about that in a bit). Looking around, it looks like it is adjacent to the turbo, right in back of the alternator, i.e., a PIA to get to, so I haven't done that yet. On the service manual, on Helm's website, it says that the print version is not available right now, but they do have on CD. However, it costs more on CD(?). I'm not sure I want it in that format.

I am currently working on Version 3 of the interior. I bought it primarily to haul motorcycles and myself to the races (besides the fact that everyone needs a van). Since I ordered it with the XLT package (I think that is what it is called), it got the headliner and full length carpeting from the Club Wagon. I put up 3/8 plywood on the side, with fiberglass insulation between the outside paneling and the interior plywood, and covered with gray indoor/outdoor carpeting that is a decent match for the interior graphite. Up to this point, I just put a plywood floor over the carpet in the back, but now I am about to embark on a silencing mission.

I have bought the foil faced foam for the engine compartment, and some PSA backed vibration damping sheet for placing on various body panels. I am seriously considering adding foam between the exterior and interior body panels. I am working out what to do with the floor. I have read about roofing material under the plywood, so I would like to hear about it's effectiveness- the vibration damping material could get kind of pricey when doing a van interior. I am going to add a partition just to the rear of the sliding door. I have bought some vinyl diamond plate material for the back (where the bikes go), and would like to have carpeting in front of the partition. I am also going to add shelves in the back as well.

Other things:
I have a dual A pillar gauge pod on order, along with an EGT and boost gauge.
I am considering an air tank and compressor. There looks like there is a fair amount of room behind the rear axle, so I am thinking about making a mount for these items here.
My fuel gauge doesn't work anymore, and I didn't like the initial quote I got from the dealer to fix it. I use the tripmeter, but I don't like operating this way. I need to fix this. I would also like to add a low fuel light. The easiest way to do this would be with a proximity sensor, but they are expensive. I could add a reed switch, but that would require making a hole through the side of the tank. I am going to have to work up my courage to do this.
I am supposing a chip is in my future, and am leaning towards Western Diesel for no particular reason. I hardly ever do any towing, and I want more power and better mileage (Duh. Who doesn't?)

I am trolling for advice, comments, criticism, etc, from the knowledgeable members of this forum. All would be appreciated. Sorry for the length

MattW
97 E350 PSD Supervan

[jt40]

Welcome to the site Matt, Wondering what your EGT's are, loaded, and or towing, over a good grade (6/9%)? I've got a 2000 PSD E-450 SD, under a 31' class c rv. I can hit 1300 on some of the tough pulls over here in AZ. Going to 4" all the way, in two weeks, to relieve it. Already done 4 gauges on the a-pillar, and a Turbo brake. Will do a WD chip, if I get those EGT's down enough. We all (PSD van owners), need to keep bugging these aftermarket performance outfits, to come up with an intercooler, to fit a van chassis application!!! Keep that rig a long time, it's worth, JT,Phx.

[The Warden]

Go with the foam. The previous owner of my van did a conversion job on a cargo van, and he put foam between the sides and the panelings he put in. He put about 1/2" spacing, I think, and, again, he injected it with foam. He went through the same thing you're doing i.e. trying to soundproof as much as possible. It worked like a charm, and he told me that when he was finished injecting foam, the van had countless little foam icicles hanging underneath. He cut the icicles off, but still...that was a lot of insulation. Granted my van's about 13 years older than yours, I doubt much has changed...and with how well he insulated the van, with everything closed, I can barely hear the 6.9l. It's also completely water tight.

Maybe I should go with a 4" straight pipe and see how quiet it is then

Just some ideas...good luck!

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The Warden

1984 Ford E-350 cargo-turned-conversion van
6.9l, C-6, 3.54 posi - Pictures
Friends don't let friends drive drunk. Friends don't let friends drive Chevys.

[ducky]

I would do a search on this entire site and the net for noise proofing. It gets discussed here and there.

I think the biggest problem is that the metal can vibrate and transmit noise. The injected foam stops this. There is another option for the floor depending on if you can remove the side stuff you put on. The spray in bedliners are being used inside jeeps and stuff now. A lot of people who did this say it cut down on noise simply because the metal does not vibrate like it use to. The guys doing the spray job don't always mask off a bed very well, so I would prep the inside of your van, or buy the do it yourself type and roll it on.

There are two things you can insulate against. One is heat, the other is temperature change. And the music recording studios often have no solids going all the way through the wall. This prevents any noise from being transmitted. Of course the acoustical foam and other stuff helps as well. You are space limited, but I think doing some research on noise reduction would help you decide what works best.

Some of the guys who get spray in bed liners say it helps on noise if they have sliding rear windows. I do not know what the best choice is. But I do know there are some other guys modifying their vans for comfort or camping, and they have used similar materials. So I would try and find those old posts and maybe email some of them and see how everything is working.

I think some of the insulation kits for motor boats are a good idea cause in those you also have a large engine near by.

[MattWallace]

Thanks, all.

My van is generally lightly loaded, so I don't expect the EGTs to be objectionable. I have the 3.55 gears, and if I set the cruise at 75, I can go from Auburn to Truckee, CA (I-80) without ever slowing down and without the transmission ever downshifting. This is 7000' ft of elevation gain in about 60 miles. I am interested in what the EGTs and boost are doing at this time.

I hate to complain (and I'm not complaining) about the noise, after the 77 GMC van I had. I think it is actually fairly quiet, but I am now motivated to make it a tomb. I like the idea of the bedliner for the floor, I think between this, some insulation/damping material, plywood subfloor, and vinyl diamond plate in the back and carpeting in the front, it will have that panel taken care of.

I got the foil faced foam and sound damping material from MSC, http://www.mscdirect.com, part numbers 1926013 and 1925411 (I would post the links, but they are a mile long). The foil faced foam is for the doghouse and engine compartment, and I think it is similar to the kits guys have been getting for marine diesels.

Here is the diamond plate: http://www.canalrubber.com/10.html

I am hoping the partition turns out really well, it will actually be a set of doors to allow access between the front and the back, and I think I will have some smoke acrylic windows so that I can still see out the back window.

Quick question: does anybody know what is between the headliner and the roof? It strikes me as a large panel that could be generating a lot of road noise.

I found this post fairly informative: http://forums.ford-diesel.com:8080/u...ML/004923.html
This guy sounded pretty rabid, and knowledgeable, in his sound reduction efforts. I am going to give some of his ideas a try. Incidently, I obviously don't have a search strategy worked out very well, I sometimes have trouble getting info I know is in the forums.

Thanks for the tips and encouragement, I am still in the brainstorming/planning stages and have only done a little building on this project. I am going to have to get some webpage skills so I can put up some of the drawings for review. The van is "medium Wedgewood Blue metallic", I really like the color, but I am going to have to put some effort into the finish, it got a little scratched up going where I last took it.

MattW
97 E350 PSD Supervan

[freeheel]

Hey Matt, sounds like a sweet van. In regards to the roofing material under the plywood on the floor. I did this. It has virtually no effect on sound dampening, at least as far as I can notice. I did it because my plywood floor is screwed to the van floor in many places and I didn't want any road spray to be able to seep up through the screw holes. Maybe this was overkill but I had access to the material (Ice Shield).

My floor is ice shield, 1/2" foil faced insulation, vapor barier, 5/8" finish grade plywood.

Definitely keep us up to date on your projects and welcome.


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2000 E350 PSD extended superduty cargo van, Quigley 4x4, 4.10 lim slip, dual alternators