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Old 05-18-2015, 07:35 PM   #1
Mini-Skoolie
 
Join Date: Sep 2014
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26' Box truck tiny home conversion project

I have been wanting to remove myself from the shackles and idiocricy of renting, roomates, and all of the facets and consequences of relying on an unsustainable energy grid and an enslaving monetary system. My goal is to create a mobile efficient and sustainable vessel that will sustain it's residents in simple comfort, yet engineered with redundant life support systems such as propane, solar thermal, and wood fired hot water. Incorporate a 500-1000 amp hour battery bank rechargeable by either 2, 400watt solar panels, and or by using the engine and alternator as a generator. Interior heating could also be achieved by wood fire / oil burner, propane heated water circulated through floors, or using hot engine coolant to circulate through the floor or route through a heat exchange to heat water circulated through the floor.

I have considered many base vehicle platforms for my ideal application including various school busses, e-350 shuttle busses, enclosed car trailers and various box trucks. I am 6'5 and cannot stand comfortably in many school busses and RV'S, so I wanted to maximize space, light, and comfort, while allowing room and weight for expansion, and the ability to tow a car or load. I also wanted one of the most powerful and reliable and efficient medium duty diesel truck engines that was not burdened by electronic and emissions controls, as well as simplicity of maintenance. I ended up deciding on the Navistar / International Harvester DT466 7.6l turbo diesel with a manual Bosch injection pump for easy power modifications and rebuildability. My ideal year range for these requirements was 1993-1995, as in 1996 Navistar introduced the DT466E with electronic control.

After looking for a truck with these requirements for four months I finally came across a bread company that was upgrading their delivery fleet and had some 20 International 4900 box trucks for sale. After a quick test drive and walk around, I ended up purchasing one of the rougher looking trucks for $4,000.Click image for larger version

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Old 05-18-2015, 07:48 PM   #2
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After doing some design in Sketch Up, here is my preliminary design layout. I have a lofted queen size bed area, with liquid storage, energy and all control systems underneath the loft. The loft is just high enough so that while in the loft on my knees, I have head room, and my cat has an extended climbing space and elevated nook. Just aft of the loft is the bathroom with composting toilet, sink, and shower. My liquid waste will be grey water as the solids will be separated and composted. Behind the bathroom is the kitchen area and fireplace, with a fold down bunk bed and desk on one side, and fold out table and bed on the other side. I have decided to flip/mirror the layout so the bathroom is on the left side and i can install a door to the curb side nexto the fireplace. More pictures and updates coming soon!
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Old 05-18-2015, 07:56 PM   #3
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One of my neighbors has a box truck thats partially converted to an rv. Its pretty cool.
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Old 05-18-2015, 08:15 PM   #4
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The box of the truck is constructed from wood composite sides with aluminum adjoining corners an aluminum roof supported by galvanized cross beams. The floor has a 2x6 wood plank base with 1/8" metal floor bolted on top of the wood planks. I plan to frame the left side of the wall with 2x4's on edge to run piping and electrical, then 2x4's flat on the right wall. I will also be framing the front half portion of the box floor, and leaving the rear half unframed metal. The roof will also be framed with 2x4's flat with spray in foam insulation with plywood over.

I noticed a few spots on the metal floor that have rust deposits indicating recurring leaks from the roof. I want to make this tiny home last for a while and thus my first project is demoing the interior and removing all old cracked sealant from the interior and exterior, and reapplying new sealant to all seams and potential areas for leaks. I began removing all the old sealant with a dremel and got each seam cleaned up for a fresh application of flash mate clear sealant. I want to use a material that is somewhat flexible with good adhesion properties while being UV and water proof. if anyone has any recommendations for interior and exterior sealant for the roof and seams, I am all ears. I feel like there has to be a paint on product instead of one in a caulk tube. I removed some corrosion and rust from the corner reinforcements and filled in any holes with JB weld, then flash mate. More updates on this soon!Click image for larger version

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Old 05-18-2015, 08:40 PM   #5
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Nice and great layup work.
The box even came with a tilt out porch! I envy that.
If you plan highway traffic, consider potential damage to the solar panels from wind, fly up debri, birds, etc.
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Old 05-18-2015, 08:52 PM   #6
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Thanks HolyBus! I can see the solar panel location as being problematic for highway travel, and the potential to be blocked by the box's shadow depending on the orientation. I am considering installing some unirack strut across the middle area of the roof to relocate the solar panels to the roof, so they could be folded down flat during transportation, while still retaining the < 14ft height clearance. Yes, the liftgate will make a nice porch [emoji41]
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Old 05-18-2015, 09:13 PM   #7
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This should be cool as hell!!

Keep pics coming
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Old 05-18-2015, 09:44 PM   #8
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Bzbussin- what is your transmission? I ask because a bread truck doesn't usually carry a lot of weight (relatively speaking) and if it's geared for local deliveries, it might not handle a lot of extra weight without some decline in performance. It won't do much good to crank up your engine if your tranny isn't up to the task.

"The roof will also be framed with 2x4's flat with spray in foam insulation with plywood over."
- if you are using spray in foam, I don't think you need to frame it first, unless it is necessary to attach the ply/covering of your insulation. I'm assuming the box is structurally sound? You do want to eliminate as many thermal bridges as you can. I believe you also said the roof was aluminum. Make sure you choose a spray that will adhere to it, will tolerate the heat of direct sun, and will be ok with the high expansion factor of the aluminum when it gets hot.

There are a couple different rubberized "paints" one brand is Bus Kote. It requires two coats and recommends a clear coat. Coverage (one layer)is about 125 sq ft per gal at about $40/ gal. I have no idea if it works on aluminum. I think it's considered a rubberized polymer? Time to google. Lol there are Utube videos with application instructions. Bonus- this product is also a reflective coating and with keep your box noticably cooler in direct sunlight.

I'm not sure where you plan to travel, but over 12' tall will eliminate a lot of routes for you. Consider getting a trucker's atlas/GPS to avoid low bridges.

Good luck with your build, and welcome!
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Old 05-18-2015, 09:49 PM   #9
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Much easier to build in a nice rectangular space. Will you have access to the back from the drivers cabin?
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Old 05-18-2015, 10:00 PM   #10
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SassyLass, the IH 4900 has a gvwr of 31,000 lbs, and has the Dana Spicer 6+ 6sp manual transmission. I will have to check the gear ratio of the rear diff. When I have taken it for a spin, I got it up to 55mph at about 2500 rpm in 5th gear. I like the benefits of the reflective sealer paint.

I don't plan on having cab to box access roach711
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Old 05-18-2015, 10:40 PM   #11
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Old 05-18-2015, 10:43 PM   #12
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this is a really cool idea, i cant wait to see how it goes for you
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Old 05-19-2015, 01:05 AM   #13
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You can find some mechanical injection up to 1997. They overlap with the electronic injection. I have a 1997 with a mechanical DT466.
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Old 05-19-2015, 02:06 AM   #14
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Awesome, thanks for that tidbit crazycal! In terms of 97 parts and hp variants, what did they offer, and what do you have? I have seen different intercooler and injection pump setups throughout the 92-97 range, for example here is my buddies nearly identical but shorter 24.5" box truck, it has a different angle attachment between the injection pump and the engine block as well as the pipe configuration between the turbo and intercooler (1st pic).
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2nd pic is my engine injection pump setup
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It's interesting that my buddies truck intercooler pipes have less 90 degree bends, if not 45 degree bends. Clearly this does not have much difference in terms of performance difference at this airflow rate.
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Old 05-19-2015, 02:33 AM   #15
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Second pump looks like mine, Bosch P-pump. That's what you want. I think mine is only 190hp because I have an AT545. YUK!!!
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Old 05-19-2015, 06:54 AM   #16
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cooler envy
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Old 05-19-2015, 11:10 AM   #17
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Better than a skoolie.

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Old 05-24-2015, 06:42 PM   #18
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Other than the fact that I have direct access from the driver's area, this is a lot like my bookmobile (on an International 3800 chassis). The square ceiling is a HUGE bonus when it comes to building out the interior walls and cabinetry.

That DT466 will clean up nice and bright. Here's mine after some Simple Green and a pressure washer:
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Old 05-24-2015, 07:54 PM   #19
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I did not see in your plans any insulation to be installed on the walls, do you plan on putting any there?
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Old 05-27-2015, 04:41 PM   #20
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Crazycal, does your engine have a sticker on top of the block that says the horsepower specs at 190? I have 4 stickers on the top of my block that says 250hp, will try and get some pics when I get back from vacation. What is the mechanical difference between these two engines, or is it all the turbo and fueling adjustment?
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