Brenda Elaine

Sep 1615 min read

From Cargo to Cozy: How We Transformed a Box Truck into the Ultimate Tiny Home on Wheels!

Updated: Sep 17

Welcome to our 2024 truck build!

We documented the entire conversion process and shared every step with you over on YouTube. For your convenience, we also compiled a list of all the products we used in the build at the bottom of this post – scroll down to shop and explore!

EP01: Building An Expedition Truck Tiny Home: The Build Begins

The Challenge of Finding the Right Truck

Embarking on the journey to build our expedition truck tiny home has been a new experience. When we transitioned from a van to a truck-based build, we quickly realized the complexity of finding the right vehicle. With our van, the decision was straightforward—a Ford Transit high roof extended. But with trucks, the options seemed endless. There were different engines to consider, various chassis sizes, and multiple cab configurations. It was a big learning curve, to say the least.

Searching for the Perfect Box

Our search didn’t stop at just the truck; we also needed to find the right box to attach to the chassis. We wanted something spacious enough to accommodate our lifestyle but not so large that it would exceed the 25-foot length limit we set for ourselves. We spent days evaluating different sizes—12, 14, and 16 feet. While the 16-foot box was tempting, it would have made the rig too long, and the 12-foot box didn’t offer enough space. The 14-foot box seemed like the perfect compromise, providing enough room for our wishlist items while keeping the rig’s size manageable. However, finding a 14-foot box was a challenge in itself as it was the least popular of the three.

Finding the Ideal Truck

After weeks of searching, we finally found the ideal truck—a 2012 Ford F550 that had been a construction service vehicle. With only 19,000 miles on it and a clean history, it was just what we were looking for. The next step was to remove the service bed and prepare the chassis for the new box. We decided to order a brand-new Morgan box, which we dropped off at a facility to have it fitted onto our truck.

Designing Our Dream Layout

As the box was being built and installed, we began the exciting yet daunting task of planning our layout. We had big dreams for this tiny home on wheels. We wanted space for a larger fridge, a desk for working on the road, comfortable seating, a built-in shower and a spot for our motorcycles. But translating these ideas into reality required a lot of careful planning and some compromises along the way.

Box Installation Complete, Let's Paint

When the box was finally ready, we flew out to Salt Lake City to pick it up. The box came in plain white, but we wanted something more durable and visually appealing. After exploring several options, including specialty paint shops and vehicle wraps, we chose to go with a Maaco shop in Layton, Utah, known for its great reviews, excellent customer service and a HUGE paint booth. The new color and protective paint layer would not only enhance the look of our truck but also provide rust prevention, ensuring our home stays in top shape for years to come.

The Transformation Begins

With the box now painted and installed, we drove to Dark Wolf Artisan in Kansas, where the real transformation would begin. Before diving into the build, we had to finalize our layout. This process involved a lot of trial and error, especially when it came to fitting everything into the actual space. We had to adapt our plans based on the reality of the box’s structure—things like where the studs were located forced us to make adjustments, such as moving the door slightly and resizing the bathroom. Despite these challenges, we prioritized keeping the living area open and functional, ensuring we had enough space for both work and relaxation.

EP02: Transforming Our Expedition Truck: The Ultimate Exterior Build-Out

Cutting Holes: A Nerve-Wracking But Necessary Step

One of the most nerve-wracking parts of any build is cutting into something new. But to create a functional and inviting tiny home, it's essential. Natural light is a priority for us, so we’re adding plenty of windows to our expedition vehicle.

Choosing Windows: Why We Went with TernOverland

When it came to windows, we didn’t have to think twice. TernOverland’s windows and entry doors were an easy choice. These windows come with features like bug screens, blackout blinds, and adjustable openings. Plus, they’re dual-pane, which is excellent for temperature control.

We’re installing two large windows (450x900mm) in the living area, one above the couch and one in the kitchen, along with a smaller window (350x500mm) in the front. Natural light is crucial, and we wanted large windows to take in the stunning views on our travels.

The entry door is another standout feature, with a sleek design and an angled window. It’s solid, with a lockable screen door that separates easily from the main door—a perfect blend of style and security. Use code TINYHOMETOURS10 for 10% off!

Adding Cargo Doors and Exterior Features

In addition to the windows, we’re installing two TernOverland cargo doors. These doors are impressive in their durability and security. One door on the passengers side will access our adjustable dumbbells drawer, and the other on the driver's side will house our grey water tank jug and access to our plumbing system. Use code TINYHOMETOURS10 for 10% off!

We’ve also added a custom-built pull-up bar. It’s perfect for workouts on the road.

Upgrading Accessibility: Torklift International Steps

To make getting in and out of the truck easier, we’ve added Torklift International steps. These steps are renowned for their strength and functionality.

The Torklift International steps feature:

Heavy-Duty Construction: Made from high-strength aluminum, these steps are designed to withstand rugged use and heavy loads.
Custom Fit: Specifically engineered for our expedition truck, ensuring a perfect fit and easy installation.
Non-Slip Surface: The steps have a textured surface to provide a secure grip, even in wet or muddy conditions.
Retractable Design: They can be easily folded up when not in use, reducing their exposure to potential damage during off-road adventures.
Integrated LED Lighting: Built-in glow in the light dark spots that provide better visibility at night and adding a touch of style.

These steps enhance our accessibility while at our campsite.

Planning the Roof Layout: Maximizing Space and Functionality

When planning our roof layout, we had a few key items we needed to make space for: a Nomadic Cooling air conditioner near the bed, as many Signature Solar solar panels as possible, a Maxxair fan, and a vent fan.

Strategic planning was essential to fit everything in. The 12v Nomadic Cooling air conditioner is a game-changer for full-time travel, especially since I suffer from heat-induced migraines. The DIY kit from Nomadic Cooling made the installation process straightforward.

Roof Rack Installation: Minimizing Holes, Maximizing Utility

To avoid drilling unnecessary holes, we installed aluminum extrusion roof rails, similar to what we had on our previous van. This setup allows us to easily add or modify accessories as needed. We custom-made aluminum angle brackets to attach the roof rack, providing a sturdy base for our solar panels.

Nomadic Cooling 12V X3 Air Conditioner

When building out our expedition truck, comfort during extreme weather was a top priority, and the 12 Volt Nomadic Cooling X3 Air Conditioner was the perfect solution. Compact and powerful, the X3 is designed for off-grid living, making it ideal for our adventures. It runs efficiently on 12V power, ensuring our truck stays cool without draining our batteries. The X3’s low-profile design fits seamlessly into our build, and its quiet operation keeps the peaceful ambiance of our tiny home intact. With this reliable A/C unit, we're ready to tackle any climate while staying comfortable on the road.

12V DC Power: Efficient operation on 12V power, perfect for off-grid use.
Low Power Consumption: Optimized to minimize battery drain, ensuring extended cooling during trips.
Compact Design: Low-profile build that integrates seamlessly into small spaces.
Quiet Operation: Maintains a peaceful environment inside the truck.
Durable Construction: Built to withstand the demands of constant travel.
User-Friendly Controls: Easy to operate with customizable cooling settings.

Cab Roof Rack: A Functional and Aesthetic Upgrade

I’ve always thought the cab and box looked a bit off when the cab’s roof was much lower than the box. So, we added a small roof rack to the cab, which not only looks great but also provides additional storage and functionality.

We included a Melipron cargo case, which fits perfectly on the standard cab. It’s a solid, well-built case with strong gas struts, making it easy to access. The Melipron brackets were easy to install with a couple bolts on the side. We also mounted All Tops recovery boards on top of the case.

To enhance the truck’s off-road look and functionality, we added a Nilight 42” LED light bar at the front. It features both spot and flood lights, providing excellent visibility. We wired it directly to our truck’s auxiliary switches, making it easy to use.

Bumper and Wheels: The Final Touches to Our Exterior Transformation

To complete our exterior transformation, we knew we had to upgrade the bumper and wheels. We found a local supplier in Kansas who specializes in heavy-duty truck bumpers and had one installed.

Choosing tires and wheels for the Ford F550 was a bit of a challenge, but after consulting with industry experts and other truck owners, we decided to stick with duallys. We opted for DDC’s rugged dually design, paired with all-terrain tires. This upgrade not only improves the truck’s appearance but also enhances its off-road capability.

EP03: From Empty Shell to Cozy Tiny Home - The Latest in Our Expedition Truck Build!

Starting the Interior Build

This build is unlike any we’ve tackled before. The main curve is at the front, but the rest of the structure is mostly square, which has made planning easier. We're excited to dive in with insulation from Vanlife Outfitters , furring strips, and wall installations. We chose hardwood shiplap from Woodplank.com for the ceiling, painting it black to fit our design aesthetic. The installation was straightforward, and we’re impressed with its quality compared to MDF options we’ve used before.

While the ceiling was being installed, we focused on insulation using 3M Thinsulate from Vanlife Outfitters. Insulation is crucial in a build like this, especially for maintaining temperature control and reducing noise.

Cabinets and Kitchen Setup

The first cabinet we tackled was a multi-functional piece that serves as a desk, couch, electrical cabinet, and bench. In tiny living, every inch matters, so we used a combination of 1/2” and 3/4” plywood to balance weight and cost. For seating, we chose a 49” Sepnine couch, which perfectly fits our space and style. It’s stylish, comfortable, and eliminates the need for DIY cushions, which can be a hassle.

The kitchen cabinets are designed to store our kitchen items and house our plumbing system. The layout balances weight distribution, with the water tank and plumbing on one side and the Ruvati sink, water inlet, and grey tank in the center. The right side features three drawers for kitchen essentials, with space reserved for our Norcold fridge.

Fridge and Countertops

Speaking of the fridge, our Norcold unit arrived, and it’s a perfect fit for our design. The matte black finish was a pleasant surprise, and it gives us more off-grid storage capacity. The size is much bigger than anything we have had before but still small enough not to take up too much space in our tiny space. We are excited to have a larger freezer space which allows us to stay off grid and out in nature longer. This fridge by Norcold is the N8DC fridge, it's capacity is 8 cubic feet! It’s exciting to see these elements come together.

For the countertops, we initially wanted teakwood but found it too expensive and hard to source. We discovered a budget-friendly pine option with a beautiful, knotty finish that complements our design perfectly. This choice was inspired by a YouTube video, and it turned out to be exactly what we were looking for.

Painting and Flooring

Inside the cabinets, we went with a golden oak stain that matches the cedar shakes on the walls, adding a cohesive look when you open them. Our original design was going to feature a dark blue and marble theme, but we pivoted to a black, grey, and natural materials look, and we couldn’t be happier with the result.

For flooring, we chose LifeProof’s scratched stone luxury vinyl plank. It’s durable and ties in with our rustic-modern theme, matching the rocks and stones around our inspiration images.

Final Thoughts

In just three weeks, the interior has transformed from an empty box to a nearly complete living space. It’s exciting to see our drawings come to life, and we can’t wait to move into our new home soon.

EP04: Behind the Build - Powering and Plumbing Our Tiny Home with Signature Solar

Powering Our Off-Grid Life with Signature Solar

Living off the grid is one of the most rewarding aspects of our journey, but it also requires a dependable and robust electrical system. That’s where Signature Solar comes in. We partnered with them to equip our tiny home with a top-notch power setup that ensures we can enjoy all the comforts of home, no matter how remote our location.

Signature Solar hooked ups up with their cutting-edge EG4 server rack batteries, which immediately impressed us with their compact footprint and high amp-hour (Ah) capacity. These batteries are designed to maximize space efficiency while delivering a powerful energy reserve, making them ideal for tiny homes like ours. Pairing these with Victron components, including a 3000W inverter charger, a Lynx distributor, and an MPPT charge controller, we’ve created a system that meets all our energy needs.

To harness solar energy, we installed five Grape Solar 200W panels on our roof, giving us a total of 1000W of solar power. This setup is a game-changer, allowing us to power essential appliances like our microwave, laptops, and even an electric oven—all while staying off the grid. The flexibility and power of this system mean we can continue our adventures without compromising on the luxuries we’ve grown accustomed to.

Signature Solar's team offered invaluable support throughout the installation process. Their expertise made it easy to integrate this sophisticated system into our tiny home, ensuring that every component worked seamlessly together.

We even added a 30-amp shore power connection with a Kohree 50-foot extension cord, a practical addition for those rare occasions when we need to plug in. The extra length of the cord offers greater flexibility in accessing power sources, especially in more challenging environments. Kohree's 15-30 adapter and surge protector allows us to be able to feel confident where we are plugging in.

Bringing Water Onboard: A New Approach

While we’ve always relied on portable water jugs during our travels, this build called for something more permanent. With our new setup, we’ve installed a 42-gallon fresh water tank, a Seaflo water pump, a Seaflo accumulator and an 8-layer Waterdrop filter. We wanted to put a water filter on the entire water system as an extra safety measure and also to keep our water system clean. The hydronic water heater system, recommended by our friend Rob, not only heats our water but also serves as our heating system, making it a versatile and efficient choice.

This is the first time we’ve had hot water in our rig, and we couldn’t be more excited. We went with a 16x20 Ruvati sink. It fits perfectly into our space, and our shower setup, though simple, is effective. We opted for a combination of vinyl sheet flooring and Redguard waterproofing membrane for the shower. This approach was both cost-effective and easy to install, allowing us to achieve a clean, modern look without the hassle of traditional tile and grout.

When living on the road, having a reliable toilet is essential. We chose to partner with Ogo for our solution, and their Ogo Origin toilet has been a game-changer. With its innovative electric churning system and urine diverter, it's incredibly easy to use.

For a simpler, more affordable option, Ogo also offers the Nomad, which uses a bag system while still featuring a diverter. Installation was straightforward, connecting the provided wiring to our electrical system was a breeze. Ogo also supplied us with their wet bath cover, allowing us to shower without needing to remove the toilet, adding even more convenience to full-time road living.

Looking Ahead: The Final Stages

With our electrical and plumbing systems in place, we’re entering the final stages of our build. The next steps involve completing the feature wall by woodplank.com, organizing the garage area, loading up the motorcycles, and tackling the last few details. We’re incredibly grateful to Signature Solar for helping us power our dream tiny home and to Rob for his expertise in the hydronic water system.

Stay tuned for our final punch list as we bring this project to a close and prepare to hit the road in our fully equipped, off-grid tiny home on wheels!

EP05: The Exciting Final Stages of Our Truck Build

The past few weeks have been a whirlwind of activity as we put the finishing touches on our expedition truck build. We’ve been hard at work completing the bathroom door, installing the electrical system by Signature Solar, and now, we’re turning our attention to one of the most exciting aspects of the build: the motorcycle garage. But first, we’ll focus on completing the feature wall before tackling our final checklist.

Creating the Feature Wall: A Blend of Tradition and Modern Design

The design for our feature wall draws inspiration from the cedar shakes on the roofs of Norwegian historical churches, with a modern twist. To achieve the desired look, we’re cutting the barnwood planks into smaller pieces and angling them at 60 degrees. We received the barnwood from Woodplank.com . In the past we have used some barnwood from major big box home improvement stores, and that quality was greatly lacking so we are so excited we found Woodplank.com. Woodplank was as excited as we were about our project, and they generously provided us with the perfect barnwood for our feature wall.

Upon arrival, we knew this was exactly what we were looking for. The barnwood has a rustic touch with one side rough and the other smoother, allowing us to stain the rougher side black and the smoother side a golden oak color. This combination beautifully ties together the bathroom door and the cedar shakes, creating a cohesive design. Plus, the wood is truly kiln-dried, ensuring durability even in humid conditions—a major plus after our previous experiences with bowing wood.

Building the Motorcycle Garage and Slim Bed Frame System

For the garage and bedroom area, we wanted a clean and functional space dedicated to our motorcycles. To keep costs down, we opted for vinyl sheet flooring, which offers a sleek look without breaking the bank. This approach allowed us to allocate more resources to other areas where we needed to splurge to achieve our vision.

To maximize headroom while sitting in bed and create ample garage space, we designed a slim bed frame system using 2x4s, square aluminum tubing cross bars, and a sheet of 3/4” plywood. This setup is not only cost-effective but also removable, making it easy to adapt the space for different needs.

Choosing the Perfect Mattress: Zinus Green Tea Memory Foam

When it came to choosing a mattress, we knew exactly what we wanted: the Zinus Green Tea Memory Foam mattress. We first bought and used this mattress in our original van build and were impressed by its comfort and support. For our truck, we chose a queen-size 6” mattress. We’ve been recommending Zinus to everyone, whether they live in a tiny home or a traditional house, because of how much we love it.

Green Tea Infusion: Infused with green tea extract, this mattress stays fresh over time, thanks to its natural antioxidant properties.
Pressure-Relieving Memory Foam: Conforms to your body for customized support, relieving pressure points for all sleeping positions.
CertiPUR-US Certified: Meets high standards for safety, content, and durability, ensuring a mattress free from harmful chemicals.
Easy Setup: Arrives compressed and rolled for hassle-free setup; simply unbox and watch it expand within 48-72 hours.
Affordable Quality: Offers great value without compromising on comfort, making it ideal for budget-conscious shoppers.

Setting Up the Motorcycle Garage

With the bed frame and flooring in place, it was time to set up our motorcycle garage. We dedicated the entire space to our bikes, figuring out the best chock and anchor points to keep them secure during our travels. Having motorcycles with us has been a long-time dream, and now we finally have the space to make it a reality.

Installing the Cab Passthrough

Before moving on to the final checklist, we tackled one last important task: installing a passthrough from the cab to the living area. We wanted easy access between the two spaces in case of an emergency, so we removed the rear window, replaced it with metal, and cut a matching hole in the box, adding an accordion boot to seal the connection.

Upgrading the Truck’s Tech with Carpuride

Our truck may be an older model without the modern features many people expect, but thanks to Carpuride’s multiplayer device, we’ve upgraded its tech capabilities. This device connects to our truck’s speakers via FM transmitter, allowing us to play music, podcasts, and even use AirPlay to display maps on a large screen.

Wireless CarPlay & Android Auto: Seamlessly connect your smartphone to access navigation, music, calls, and more without the need for cables.
9-Inch Touch Screen: Enjoy a clear, responsive display that's easy to navigate, providing a more enjoyable and efficient driving experience.
4K Dash Cam: Equipped with a built-in 4K dash cam, this device ensures high-quality video recording, offering peace of mind on the road.
FM Transmitter & Bluetooth: Stream your favorite music and calls through your car's audio system using the FM transmitter or Bluetooth connectivity.

The wireless backup camera was a breeze to install, making this a major comfort upgrade for our travels.

Adding the Finishing Touches

In the last few days, we’ve wrapped up the painting, installed the couch, and added small shelves for our plants. It’s all coming together, and today is a big day—we’re nearly finished with the build, and Abe is taking charge of his favorite part: decorating the truck.

With the final touches in place, our expedition truck is ready for the adventures ahead. We can’t wait to hit the road and explore new horizons with our fully customized tiny home on wheels!