Van Build
The Shimmy Shack
A 2025 Ford Transit high roof extended. Katie and I are building it out ourselves — picked it up March 2025 and have been at it ever since.
The Van
Model
2025 Ford Transit
Config
High roof, extended (22 ft), AWD
Engine
EcoBoost
Extras
RV package (swivel seats, big mirrors), second alternator & battery
Roof
Flatline Van Co. low-pro rack + ladder, 400W solar, Starlink
Odometer
~2,000 miles
Nights slept in it
~14
Trips
Shakori Hills (×2), Charleston SC, local
Layout decisions, measurements, and way too many YouTube rabbit holes. Layout mostly settled: kitchen by the sliding door, bench seat with slide-out fridge opposite.
Stripped the factory liner, treated the metal, and got everything ready for insulation.
Butyl for sound dampening, Thinsulate for thermal. Most walls and ceiling are done; the headliner still needs to come out, and the floor is bare metal.
Bluetti AC200L (2048Wh) + B300K expansion (2764Wh) for ~4.8kWh total. 4×100W Callsun panels wired in series on the roof rack. Shore power port at the rear bumper. A Victron 1200VA pure sine wave inverter handles drive-charging (the van's built-in inverter isn't pure sine and won't charge the Bluetti). Starlink and solar are fully wired; everything else is temporary until we decide whether to stay with the Bluetti setup or move to a traditional 12V system.
Custom insulated covers for every window. Half of the rear windows done; front windows and windshield still to do.
Insulation board over the bare metal, then a plywood subfloor, then a vinyl finish layer.
Three windows to install: one in the sliding door and two bunk windows in the rear, all operable for ventilation.
Walls, ceiling panels, and headliner — after the headliner comes out for final insulation.
Kitchen by the sliding door. Opposite that: a bench seat that converts to a bed, sitting above the ICECO 75L dual-zone slide-out chest fridge/freezer. A composting toilet will likely tuck in between the fridge area and the bed. Layout is mostly locked; build hasn't started.
A roof fan over the kitchen area and an under-bench AC unit — keeping the roof clear for future solar expansion.
Before It Gets Hot
The goal for spring (by June): finish insulation, get all window covers done, and get the floor up through the subfloor. That makes the van comfortable for summer trips while we figure out the bigger build decisions.