Adventure Wagon Interior Conversion Part 2
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May 3, 2025
Today Nick at Van Builder HQ is showing us how to install a camper van interior conversion kit by Adventure Wagon. This is part 2 of the series. Visit https://www.vanbuilderhq.com to learn more. Interested in buying a van? Check out https://www.odysseycustomvans.com Support Van Builder HQ on Patreon: https://www.patreon.com/vanbuilderhq
View Video Transcript
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[Music]
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hey guys welcome back to our adventure wagon interior conversion kit we're moving into part two and we are
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finishing up this driver's side over here if you guys remember last time in part one this driver's side was not
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finished because we needed to have access to these two holes right here in order to get our
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insulation to feed in the back so this is what the insulation looks like
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it's made by 3m and it's really popular the van community
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because it's hydrophobic which it does not like to
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hold water or get wet if it does get wet it dries very easily
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doesn't mold so a lot of people like to use this it is more on the expensive side but
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i think uh the benefits outweigh the cost on this product anyway you're going to get this with adventure wagons kit
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you're going to get enough for the whole entire van so the reason i paused on this and it's not
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part of the part one eventual wagon install is because like i said you need to get access to this hole here and up
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here so right now we just have this held on by painters tape a set screw here and then a set screw
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back behind here and then what we're going to do is uh in the instruction videos
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let's say the best way is to get like a long uh rod or a piece like all thread or something like that
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and be able to put it in this hole and then actually push it through this cavity
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and then that's part one and then you have a second piece um and then i'm just going to do the
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same thing and that way we have both of these pieces of insulation back behind here
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so that's the first thing we're going to do today and the second thing is we're going to put our hush mat just in this top
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section and then we'll follow it up by putting in
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piece of insulation that goes into that cavity this is nice because you've got a lot of room to work with back here
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but once you have this part in you won't be able to move it around this there's a little beam back here so to gain access
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to it that's why i haven't put this piece on but once the hush mat is in
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once the insulation is in we'll rivnut these
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this one actually does take rivets so i've got a couple here that we got to put in
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and that piece actually serves if you saw in the first video it
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actually serves as the cable tray so this cable right here will actually
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be supported by this once it goes in
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and it's going to go in just like that now again as you're working on this kit
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be very careful there's all kinds of little spikes and sheet metal the sheet metal is extremely extremely sharp so
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just make sure that you're taking all the precautions you're wearing the proper gloves don't cut yourself i cut myself a couple
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times and i've done this a couple times so yeah make sure you wear gloves it's very
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sharp so we're going to knock that out and then once we're finished with that
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the good news is our aw 1033 windows from cr lawrence came in
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and we've got all those for this van so we can go ahead and start templating out where the windows are
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going to go and once we know where the windows are going to go like for example this one that's over the kitchen galley
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we can go ahead and start doing the rest of our hush mat after we cut the windows out so the
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reason i'm holding off and putting the hush mat in right now is hush mount has like it's
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like a tacky texture if there's any metal filings that are cut off from the window
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they're going to adhere to that piece of hush mat the tacking part
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and those are raw filings raw steel filings so they will rust over time with
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moisture that does come through the wall that's one thing you got to deal with vans is
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controlling the moisture making sure you're always ventilating with the roof vent because this is a pretty sealed
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environment and with you breathing and exhaling it's putting a lot of humidity into the
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van so you want to make sure your fan's on as much as you can do it you're always ventilating so that
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you don't have any rust issues so we prevent that by putting rust
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prevented on every single surface that is not painted or surfaces that have been drilled into or
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riveted just to make sure they don't rust so those metal filings
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adhering to the hush mat we want to prevent that by doing all of our cutting of these windows first cleaning
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everything out vacuuming blowing it down wiping it out and then once we're finished with that we can actually go
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through the van is clean we can put the hush mat in then we can put the insulation in
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and then we'll move on to our final and third part of the video which is in
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installing the rest of the panels the actual upholstered panels so we're going to go ahead and knock
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this out get this complete and yeah that's going to be our next step all right guys welcome back we're going
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to go over a couple of things that we're going to use to install the hush mat it's the first thing we're going to do we're going to install it back in here
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and if you don't know what hush mat is it's essentially a material that dampens
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the sound and it does that by changing the frequency of whatever or the resonant
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frequency of whatever material you're putting it on for us we're putting on sheet metal and
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this is a big fancy way of saying we're taking something that is a high pitch noise
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and we are turning it into a lower pitch noise so we're taking the vibration and
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we're slowing it down so it's more like a thud instead of a ping like tinty sound
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that sheet metal sounds like if you don't take care of it with this type of material
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now in the past if your car audio guy or girl you may have used the product called
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dynamat and that's used for like trunks and doors of cars so that if you have
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subwoofers in your car the whole thing doesn't like rattle pieces uh it's the same exact thing same concept
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so we're using the hush mat hush matt is what comes in the adventure wagon interior conversion kit and it's much
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thinner than any dynamite that i've used and what's nice about that is it's really
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easy to work with you can actually cut it with a pair of scissors
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these are actually carpet shears so they're pretty heavy duty most people won't have those but if you
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have some of these there's some old school carpet shears that my grandfather used i still have
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they're super sharp and then you're going to want to use this one of these rollers here if you guys
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could see that this is just purchased off of amazon and i've got like two of them
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if you're in a pinch you can go to michael's or hobby lobby and they do have these rubber rollers
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the handles are not so good on them but if you earned a pinch
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you can use those and we're going to open this up here
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so you can see we got a rubber roller all right nice wooden handle so you can grip it
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and then what we're going to do is we're going to cut this material to size
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and we're going to stuff it up in here i haven't cut it yet but we're going to stuff it up in here
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and then we're going to push it down and remember the
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sheet metal is extremely sharp so you got to be very careful when you're putting this in here but we're going to
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go ahead and get this piece cut and you want to look at the top
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and right here there's a there's a bar behind here you got to watch out for so this bar
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you can go up underneath it so that's what we're going to try to do and then down here at the bottom if you look
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we actually end right here that's where we end
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so from here to here you cannot access all the way
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in the bottom so since we know that we're only going from here to here we'll go ahead and
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take our hush mat and we're going to cut it um right here
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and that looks like it's halfway so let's just double check that see if we can just cut
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perfect yep so we're just going to fold this in half and then we're just going to cut right
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down this seam right here
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and what you can do is you can you can have like a cutting board or
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cutting mat and cut this out if you want to but this hush mat it's so thin that
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it's no problem and i'm actually going to move the camera just a little bit
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there we go perfect okay
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so we got it cut got our piece and so this one should fit
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right up in here um i'm probably gonna do this side first then this side and then i'll get another
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mat i'll cut it in half and i'll put one more piece right here and so
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uh so what that's going to do for us is this noise right here
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that tingle we're going to tap it again after we put this hush mat in you'll see the the
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difference that it makes
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and then so right here just going to peel it off now i keep saying be careful with everything sharp edges so this is
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actually a foil backed piece and this edge right here is also
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extremely sharp so just be careful
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and a couple different ways you can do this you can you can peel this whole thing off or you can do this just to get it
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started up in there and then fill it down from the bottom so that's what i'm gonna do that way if
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i need to reposition it i can do that so we're going to go ahead
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and we're just going to stuff this up under this beam right here
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[Music]
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okay we've got all of our hush mat in on the top so we're gonna go ahead and put our insulation in
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and then we'll move on to installing this bar
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right there
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so one thing i did was i took the whole entire cardboard box apart i laid
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everything out on the table and i did that so that i could organize
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visualize where everything went in the van so i got everything for the top panels i got the
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middle part i got the bottom part driver side versus passenger
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and even the ceiling and then the headliner so all that is on the table
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organized so once i get done with the windows the hush mat i know exactly
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where the insulation is going but the main reason i took everything out of the box is because
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the the way that they name all these pieces like d dash top dash 1a
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and then this is d dash top dash 1a
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but this is labeled part 3 this is labeled part 5.
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it's not very clear what piece goes where and
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since everything is pre-cut if you put something in the wrong place because it looked like it fit but it
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didn't go there and you're going to run out of it somewhere else so what i did is i needed to find this piece
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this piece the name of it is it's part one and two
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and the part one says d dash top dash h o r for horizontal dash c
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and this is d dash top dash horizontal dash d so horizontal c horizontal d drivers
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drivers top top so i got that but when you're going through all of the other codes and stuff like that
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the videos that i've watched online they don't really clearly show exactly where everything goes so
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i'm doing my best on this 148 inch to tell you guys where
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each piece is going in the van just to help out but
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if you lay it all out on the table it'll make it much easier because you can visually see where it goes in the van
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and then you actually really don't have to worry too much about what these numbers say
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anyway a long-winded way of just saying hey lay everything out you'll find where it
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goes and then and then you'll know so these two pieces
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again they're number three and five and one is driver's top 1a driver's top
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1a okay so we're going to take these and we're going to put both of these
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inside of here because if i go over here
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coming back we have the same for we have the same for passenger top
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1b passenger top 1b so these two
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will go passenger top right there so now we know that we have our we have our part for the opposite side of the
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van so that we can use both of these because as we get further along in this
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build what you're going to find is depending on how you're cutting windows
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out for your van if you're replacing this slider door area with like a t-vent window which i'm
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doing you're going to start to have extra insulation so
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you know you can use it somewhere else in the van because the windows are there same thing for me once this window gets
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cut out there will be no insulation here so yeah you'll be able to use it in
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different areas but if one area has two layers like this that's good that's a bonus in my opinion
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anyway let's go ahead and put this in and we'll keep going and the way that i'm going to put this in is i'm going to put it through this
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middle part and then i'm just going to pull it through and push it over there and you can actually see my arm
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goes all the way to my elbow so that's how much room we got
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so we can just put this here where my elbow is and put this up here and
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that is pretty good so if you guys want to
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you don't have to be as detail-oriented as i i am but uh if you want to you can like
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fold it and put a piece of tape and that way you know that you got this
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you can have this land where you want to so say you want it to land right here and this is
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where you want it to stop you just get a piece of tape on there go ahead and
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pull this through again watch out for the sheet metal
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okay come through here
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and then the bottom and top ends just watch out for them because they're what's going to uh
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get jammed up so get that in where you want it
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again we got a big bar here so we need to make sure that we get behind it
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and actually what i'm going to do is i'm going to have the left go all the way there
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but then on this right side i'm gonna try to stuff i'm gonna shift it over a little bit to
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the right so this is our tape we had
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i don't need that okay so now we're to take our other piece and do the same thing
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and just watch your piece behind it to make sure you're not dragging it
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and i'm sure there's different ways that you can do this but this is just the way i'm doing it
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so
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yeah so i'm really getting that in that cavity up there
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i'm actually going to pull this towards me a little bit i really get that air space
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so don't want this stuff smashed together if you're actually putting windows in
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and you have the bump outs on the back you're going to want you're only going to want to use one layer of insulation
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because the way insulation works is it traps air
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and if you compress it there's nothing inside to actually hold air
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and air is the insulator so if you smush it you your insulation value goes way down
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so just like if you're you got a sleeping bag and you're going hiking you want to keep your sleeping
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bag lofted after you're done hiking you don't want to keep it crammed in a bag same concept with this stuff you want to
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keep it to where it's nice and lofted not smushed in here so that's why i'm kind of
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pulling it out i mean just almost like a pillow you know like fluffing a pillow
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so now we got nice nice loft nothing smushed we're gonna have good insulation back
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here all right next step we're going to
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take our piece right here again we're in the 148 inch
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transit 148 inch wheelbase we're using
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th12 and th12 right here where i have this permanent
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marker that's where i had it prior this th12 is going to go right here
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a little foot it's going to help you keep it uh where it needs to go don't don't worry about
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this do that later that's that foot and then over here
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we've already made sure that it's level
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uh or where the holes need to be so that's there so we're going to get our clamps we're going to clamp this
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into place we're going to finish drilling our holes and then we're going to get the
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riveter we're going to rivet this thing into place so these clamps that i'm using
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these are just like clamps from lowe's or the dewalt brand you can use anything i got some stuff
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from harbor freight but what's nice about these is
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especially if you're one one person installing this by yourself
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it'll really help you just get everything exactly where you need it to be
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and it'll keep it out of the way for when you go to actually
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drill or you're riveting these pieces together
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put it right where our line is
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and as you crimp down on this it will drift so just make sure you correct it before you actually drill the hole
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and actually one's just really one's holding it down so don't need that one
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the next thing we're going to do is we are going to
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yeah we're going to get our rivets and we have a pre-drilled holes right here
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and so that's what we're going to use to put our rivet into now this piece has rivets
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this piece has the rib ribbed nuts
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so a little bit different but most your pieces like you saw in part
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one are going to have the rib nuts not the rivets this one is just rivets because
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there are no existing uh factory holes to enlarge so we've got a crater hole so we've already got those
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in there so we'll go ahead and we'll do that and uh
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before we actually rivet this we're going to take this off
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because we have to do our rust preventative don't forget that
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all right in this next part i want to make sure that we uh show how we
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do the rest preventative it's really extremely self-explanatory but
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it is a process that i've found so easy that i kind of forget it and sometimes i miss it so
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uh and i actually have to right before i put this on
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go back and then do it so every single one in this van is knocked out i've got it but i just
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know it's really easy to miss this step so make sure that this
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rust preventative that you get in the kit they give you a brush but you can use
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any type of painter brush make sure you use this don't forget to use this it's really really important
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so i'm going to show you what to do so we went ahead and there's another tool let me get that out
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so this tool right here in the camera this is called a deburr tool
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okay and what this is going to do is it's going to take off any burrs that you have
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on the holes that you drilled out right up here so we have our
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three holes and remember these holes are going to be
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different than the rivnut holes because we're obviously going to be riveting them in here
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so these rivet holes what we're going to do is you're going to take this tool you just put in the hole
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you just rotate it around a couple of times clean it out
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and just getting those burrs out so the rivets gonna go in nice and clean and then the next step we're going to do
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is we're going to do the rest preventative first so we're going to open the bottle
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now this stuff will turn black so it's like a milky white when you first get it
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and then as it ages it turns black
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so it's kind of like a it's kind of like a
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get that focus it's kind of like a gray gray color right now and uh but what we're going to do is
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just going to take it on the brush
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and then really simple we're just going to go through put it through the hole and just do a little twist
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get some more and don't you can be generous with this stuff
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don't worry about not being generous okay and i'll show you why we're being
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generous here in a second so i do that that way i get the front face because if you put
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if you put this on and then to the rest preventative there's a gap
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that doesn't get rust preventative on it
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so if you drip any of this on the floor it's gonna i'll show you different part of the van
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it's gonna turn black and that's okay so it kind of goes on clear or milky
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white and then it turns black but once it turns black that means that it's protected
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okay so we're gonna take our piece just like we did a couple seconds ago i'm going to put this up here
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get our holes lined up
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then we're going to get some rivets to make sure the alignment's correct
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and so some will go in
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okay for example these went in this one
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so yeah probably one of these is going to be a little tough that's okay
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because all we're going to do is we're just going to i've got a little bit of tape behind here
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to catch any filings that might come out from the drill bit
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and we're going to take our solid carbide 3 16 inch drill bit
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solid carbide very very important this is boron steel up here
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this is more like regular steel down here but this boron steel is it's extremely hard to drill through
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so we're going to put up here and we're just going to get our drill
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that's it we're just kind of chasing that hole to kind of get us back to where we want
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to be um and before we put a rivet in it let's go ahead and test it there we go
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so that's in so i'm going to keep these two in and this is the one in the middle is one
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that's the one i'm gonna rivet first to the wall and so we got everything in we got our
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we have our we've got our hush mat we've got our insulation so we don't have to go through this uh
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access hole up here everything's good to go and we're gonna take this middle rivet out
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and we're gonna take our rust preventative
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just going to hit that hole one more time
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don't worry about being messy when this dries it'll be a black ring that's okay
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that is the rust preventative doing its thing
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and then we're going to take our rivet and we're going to go get our air compressor line
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and we actually have two air compressor uh
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our air rivet guns uh one that we have this is a 3 16
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and the other big one that's really nice to have for the roof
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or the ceiling of the van this is a this is a quarter inch
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rivet
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so we're going to take this [Music] and we're going to go ahead
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our safety glasses on we're going to take the rivet right here i'm going to put in the gun
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right there and then we'll take this we're going to push it straight into that hole and i'm going to get my gloves on
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so once you get a process to this a method to this it goes much faster
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obviously this is for educational purposes so i'm going a little bit slower here
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we got our gun put my gloves on because i'm going to be grabbing this right here
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and then i'll put this in i'm going to push forward
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one pull two pulls it pops off
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and then when it'll come out the back so you don't want to scratch anything just
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go ahead and let it fall in your hand [Music] okay so now that we have this in place
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okay we can just we can pick either side i'm probably going to go with this right side
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and i'll take that rivet out make sure
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we rust prevent so you got a rust preventative
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don't forget the rust preventative
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all right
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our gun and go over here push it in
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and then we have a right underneath here i don't know if you guys can see it but right under here
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we have the permanent marker line that we know is our level point
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and so we just want to make sure that that is where it needs to be push in
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and then we got that riveted right there
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okay that's good and we can actually take our
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thing that held our metal dust a little piece of tape take that off
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then we'll move over here to our rust prevent and then we'll do this last we'll do this last one
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and sometimes you may need a pair of pliers to get this out that was holding the spot
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because this these kind of change where it was
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don't forget rust prevent i'm going to say it like a million times
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it's so important
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let's put that in the hole give it a little spin
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[Music] it's in here
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hold the van and push in
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all right so now we have our upper bar ready to go
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take the clamp off okay so we're done with this upper part
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got this down now we're going to move on down to this part so now we can take our tape cable tray
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just stuff it up here where it's going to go take my clamp off i was using that earlier
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okay so now we're here and this will be our next step
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okay now we move down to this bottom side we have a set screw here and then we've
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got another one over here and like in part one those are going to allow you to temporarily hold this in
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while you drill these holes out so now we're going to go ahead and undo
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them and we got painters tape up here just going to help us out so it doesn't fall
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on the floor shouldn't fall on the floor
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now we just lift up this part comes out when he's laid on
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the floor and now here's that hole that i was talking about so this hole is open now
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now we can actually stuff things in there and this is the only way to gain access
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to this and what we're going to do is we're going to get
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a piece of threaded rod or whatever i have in the shop we're going to stuff this through here
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and have this make it all of it make its way all the way to here about right where this hole is and then that will stop and then we'll
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do the same thing for the second piece and then that'll allow us to uh get the insulation in here
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all right so i'm gonna try this i got this piece of uh there you go i get this piece of pvc
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it's actually what i use on the corrugations in the van floor to actually level the floor out it's really great
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because it's pvc it's not going to rot but it is stiff enough and flexible enough that i can actually
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get it all the way in here because you've got to have a constant
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bend as you come in and then i get a little mark right there that i made if i take it out
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i'm actually making it all the way to the inside
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so what i'm going to do is since i want this to be half the
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distance so this is the final part's gonna be
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like this so i really just want to have the uh this first piece
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pretty much go to right here so we can measure that
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and we want this bar to stop
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wrap this on here okay so we want this to stop but right there
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yeah so actually we want it to stop right here so we're going to put a piece of tape on
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it right here so that we know that's as far as we want to push it
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i'm just going to take a piece of painters tape i'm just going to tape it
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just like that right there
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make sure it's in focus
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then we're going to take our number one piece driver's top horizontal c
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all right i'm going to flip it over here
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like that okay
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so that way we actually have it flipped over the bar we got it halfway
40:03
and then this blue piece of painters tape that's going to actually tell us where we're going to
40:08
stop right here so i only get one time one chance to do
40:16
this
40:22
and you don't want it to go like this you want it to be vertical so you want it to maintain like that on the inside
40:31
as much as you can so let's see if we can do that
40:38
i'm just stuffing the bottom and stuffing the top as it goes
40:49
remember to wear gloves because you're touching that sheet metal
41:06
okay so when we get it in make sure you don't push it like pause make sure you're nice and vertical
41:13
and then we're gonna take it we're gonna go where the blue line meets right here
41:19
i'm gonna push it in
41:24
yep i'm gonna stop right there
41:29
then we're gonna come back or just a little bit further
41:37
all right i'm going to come back so now we know the end of it
41:44
is right here at the end that insulation in there
41:49
but now we're going to take the second piece we're just going to do the same thing this is
41:55
number two drivers top drivers top horizontal d
42:51
okay we're actually going to stop right there and we're going to stuff this right behind here
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so just a little bit more okay right there
43:02
i'm gonna take this out
43:07
pull this one back and we're gonna stuff this one in that goes in the back section
43:16
and then this front part just goes in the front section
43:22
and we'll just get that a little bit
43:28
okay so now we have insulation all the way up into here
43:34
okay so that is good all right so next we're going to
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make sure that we rust prevent these holes
43:48
and then once we breast prevent we're going to put the piece up and then we'll revenue everything back
43:54
together okay we got a rust prevent open it up
44:03
and we've already pretty much went ahead and we've got all the
44:09
[Music] let's do this one more time
44:20
that's pretty much all of them a little bit of deburr
44:28
if you leave your brush for too long this is actually going to get really hard on it so you just put it back in here get it wet again and
44:35
it should loosen up on you so we got one here we're going to do
44:41
liberally liber liberally add
44:49
the arrest preventative
44:56
don't worry if you go outside you will not see it
45:12
and then your set screws also rust prevent where you drilled your set screws any
45:18
raw metal just put this stuff all over it
45:26
okay all right so
45:34
looking good
45:44
okay grab your set screws
45:54
set our piece back up here
46:23
painters tape is nice it holds it right in place
46:53
i'm going to get out our rust pregnant one more time
47:02
and hit the inside
47:28
okay and then the next step we're going to get our rib nuts get those into place we get a rivnut
47:34
tool that attaches to our drill we'll go ahead and set those into place
47:39
and then this will be complete and then we will move on to the next portion is we need to
47:47
locate this roof vent by putting in our top ceiling
47:52
panel and then that will be the last hole we need to locate uh and then
47:59
the next portion of this video will be going into doing the layout to cut out all the
48:04
windows in the van so pretty excited
48:10
so i was talking earlier to you guys that i had a special tool off of amazon
48:16
and this is the astro pneumatics xl rivet nut drill adapter
48:22
it's model number adn38 and i'm sure i'll have a link here somewhere
48:29
it does m5 m6 m8 and m10 and i believe today we are using
48:36
m6 so these little rib nuts are m6 rib nuts that
48:43
we're going to be using in this drill the way it works is
48:49
you reverse it and the stem comes out and then you can actually
48:56
see there you go so you reverse it
49:02
the rib nut the rib nut comes off and then
49:07
and then when you put it back on you'll just put it on the tip right here
49:12
and then you'll actually drill it forward
49:18
and then it'll catch it uh and then that'll be on the it'll be on the tip
49:26
and then you'll take this and then you're gonna put it right in if you guys wonder what i'm doing i'm
49:31
looking at the monitor make sure everything's in focus so you're going to take this go straight
49:37
into the holes doesn't matter we've already done our checklist we've
49:42
done the respirative so we're going to put this in here everything's lined up get our set screws
49:49
all good and you're going to have to practice with this a couple times to understand
49:54
the clamping force it's more of an audible
50:00
noise but you're just going to get in here and then it's going to catch and then
50:06
you're going to hold you're going to hold this part of the drill
50:16
and it's just one three three clicks
50:21
and then you're just gonna reverse it and then this guy is not going anywhere
50:28
[Music]
50:51
all right guys down here at the bottom of the video we are working on sizing up this top up here for our ceiling and we
50:58
want to put the ceiling pedal in so we can locate our hole for the max air fan so we'll go ahead and take a tape off of
51:04
here and i've loosened this side and so i'm just working over here on this other side
51:10
getting this tape off of here fortunately i use very cheap painters tape to protect this
51:18
and it's not coming off very easy but it is protected so
51:23
i guess that was the whole point um but we're going to get this off all
51:29
the way to where we can access all of these screws
51:34
and get it loose so that we can actually lift up the panel up in here
51:41
and i'm not taking all the screws out i'm just loosening them up a lot
52:27
all right guys we have this installed as you can see and every all the corners are nice and
52:33
even especially over here these gaps are all even the best part about this is back here
52:43
where the fan goes so we get the rib and we got this cut
52:49
out directly directly on this
52:55
rib right here so it's exactly going to be exactly 14 inches from there which is excellent i'm
53:01
really glad they did that i don't know why i would think they would do it differently
53:08
but yeah that is what they did which is excellent so
53:14
we will yeah take it from there all right so to finalize this video what
53:20
i'm going to do is i'm going to right here i'm going to trace this out
53:25
and get that all ready to go and then in our next video what i'm gonna do is
53:33
uh that will be doing the um [Music]
53:39
hush map for the rest of the van i'm sorry we'll be cutting windows out
53:44
we'll be doing hush map for the whole entire van we'll be doing installation and then we'll be doing the final
53:52
upholstered panel installation and then we will be done with the adventure wagon
53:57
system really cool so that should be all done by the end of next week and then we'll
54:02
go ahead and knock out um oh by the way cutting the windows out is
54:09
not part of the timeline for the adventure wagon install so it's completely different
54:14
so the time that it should take to do the venture wagon no windows is different obviously than when you're
54:20
cutting out one two three four five holes in the van which is what we're doing
54:25
so stick around for that that'll be coming up in the part three of this series
54:32
and uh yeah stay tuned for that it'll be coming out very soon maybe already here at the end of the
54:38
video so click on one of those links you can watch part three of the adventure wagon interior conversion kit
54:46
[Music]
55:05
you