Ka'a Nui - The Big Van Project 2024 - www.johnconey.com/kaanui_home.shtml
A blog about the setup of the RV Ka'a Nui, a 2021 Dodge Promaster van purchased on February 28, 2024. A huge hand goes out to Howard and Tim, who drove me to Kona to meet the seller and have lunch. Great people and tons of fun for sure. The van is a tall 9-4" Promaster van with 136" wheelbase (wb), front-wheel drive. For electrical, it supports a 230a high output alternator and 700 watts of solar (more on that later).
Sooo, why buy a van. The current concept is to fix and build it out into a sleeper van to include a bed, toilet, sink, fridge and other amenities and ship it to the mainland in a few years when done.
June 22, 2024
Progress happens, finally got a weekend of sunny weather to work on solar. Cut three holes, added grommets to protect the wires, and cleaned up the solar wiring. Now bringing 8awg line into the van, and connect to a breaker panel. Now powering a 45-quart fridge on the yeti500 controller and is working great.
With solar complete, working on finishing the ceiling. Pushing sound-deadening mats to the ceiling then will put up rock wool insulation. The start of side panels for the cabinets are in, and looks sharp.. Photo of Janet putting on the nice spar finish over the gunstock oil-based stain. Nice job Janet!
Replaced all filters and got in an oil change. Also added some new side runners to help step up into the van more easily. Seems to really help. Now the owner of an 8" memory foam mattress, ready to be installed, but a bit more woodwork first.
Ceiling is the next big step, and that is close. Stay tuned!
Ceiling update 7/14/2024, most of the main panels are in, lights cables are ready for lights, and fan housings are installed.
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| July 15, 2024 |
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| July 16, 2024 |
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| Lights are in, and Dimmers work! |
7/17/2024, Next up, cabinets and water tank!
8/9/2024, Much to report. The water tank system was tested and installation started. Also upper cabinet was built and dry-installed.
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| Stained, coated, and looks great. |
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| Front side, sans the locking buttons. |
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| It works! Will add hydraulic lifts later. |
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| Locking buttons are super cool! |
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| Soft hinges are great! |
September 1, 2024
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Camping at Kalopa
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We took Ka'a Nui to Kalopa this weekend. Fun trip and the van worked great. New 8" memory foam mattress was installed, and hydraulic lifters in cabinets are in. Good trip, the power worked well, through the night and the next day. Only to realize I had the solar panels off (turned off the breaker). Monday Installed over sliding door cabinet and light, works great.
Next... Driver's side cabinets are going in. soon...
September 12, 2024Progress, as the final pieces of ceiling trim are installed. Also ran the roof LED monster light to the front of van, and only need to figure out what location for the switch to be installed. The drivers side cabinets are coming along swimmingly, and I hope to finish trimming and staining this weekend. I think all parts for charging are in, so need to lay that out and get ready for install.
September 22, 2024
Progress happens... Got the light bar wired up. Looks great, hope we don't blind anyone... The switch fits well and seems to not get kicked on by any cups. I might build a safety to keep from accidentally turning on. It is tied to the vehicle power, so no key no light.
Also progress on driver-side cabinets and they are just about ready for cabinet doors. These were a bit more tricky to install as had to build in place.
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Janet did an amazing job on the rear door panels. I was supervising (not), sitting and drinking morning coffee... Next up are the rear folding tables that will be installed.
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| Driver-side cabinets taking shape. Doors and hydraulic lifts on the right side, soon to follow on the left side. |
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| Cabinet doors needs parts yet, but closer |
3 October 2024, cabinets are in, well the doors are, need to install hydraulic lifts and closing knobs. Also supports for inside and edging strips to be installed. Next up Lower cabinets designs and with that running of the electronics, 12v and 110v systems.
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| 10/15/24, front panel under bed staining. Janet does a great job! |
October 26-28, 2024, plumbing and electrical kicking in!
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Main DC distribution panel
installed. |
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Backside of panel, needs (-) buss bar
installed and various 12v things,
pump, lights, usb chargers, heater, etc. |
DC2DC 50amp controller, 2k inverter,
and bus bar system. Battery is temporary.
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| Water pump and plumbing started. H2O heater in foreground. |
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| Master carpenter hard at work! |
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| Bulkhead installed, 3/4 solid with hatch to access the trunk. |
1/24/2024 - Holy Floor Janet, or There's a Hole in the Floor dear Janet...
We cut holes for our Velit 4000 watt heater adjustable for altitude. Lots of tape and cardboard and back and forth under the car to make sure we cut once, and measured 200x...
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| Creepy people looking up from under the van... |
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| Ehh, who's that looking down at me! |
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| Ohhh boy, I hope this works out. |
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| running out of room. Fridge, heater and more stuff to go... |
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