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Old 09-12-2011, 19:20   #1 (permalink)
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Default M820 RV build / M4 Van body Build

This is going to be the thread for the deconstruction and rebuild of my M820A2. The M820A2 is a variant of the M809 series 5 ton cargo truck often used for hauling calibration equipment and as a work area when in the field. Common uses also included a temporary holding area for detainees and temporary lodging when in the field.

The common issues with the M4 van body also used on some trailers and the M934 5 ton variant are leaks, insulation and damage caused to the expansion mechanisms. The time and number of able bodied people needed to expand and contract the shelter is my main issue and hence the various modifications I will be making to the box.

I will be adding further modifications to the vehicle as well such as lockers an engine swap, cab insulation and what ever else I end up having time and or money to shoe horn in.

What follows here are pictures of the rust damage and structure of the box itself. A lot of people have asked me in the past what is under the plywood and how strong the box is. This should answer those questions and then some.
Attached Images
File Type: jpg Box_Interior_1.jpg (62.3 KB, 233 views)
File Type: jpg Box_Interior_1a.jpg (53.8 KB, 240 views)
File Type: jpg Forward driver corner.jpg (77.1 KB, 231 views)
File Type: jpg Full van view.jpg (50.6 KB, 226 views)
File Type: jpg Side wall 1.jpg (69.0 KB, 220 views)
File Type: jpg side wall locking mechanism.jpg (102.6 KB, 217 views)
File Type: jpg Window assembly.jpg (63.9 KB, 197 views)
File Type: jpg Ac unit image 2.jpg (67.9 KB, 194 views)
File Type: jpg Ac unit image 3.jpg (82.8 KB, 183 views)
File Type: jpg damage 1.jpg (95.7 KB, 190 views)
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Old 09-12-2011, 19:21   #2 (permalink)
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Axles and NTC 350 engine both PRE rebuild. Axles reportedly came from a Chair force fire truck. Picked them up for the lockers mostly.

20 Feb 2012

Added pics of the sand blasted axles and first shots of the heads as they were being removed.
Attached Images
File Type: jpg 004.jpg (72.1 KB, 73 views)
File Type: jpg 005.jpg (70.0 KB, 69 views)
File Type: jpg winch.jpg (79.7 KB, 64 views)
File Type: jpg mounting hardware.jpg (42.9 KB, 60 views)
File Type: jpg 001.jpg (58.1 KB, 65 views)
File Type: jpg 002.jpg (70.5 KB, 67 views)
File Type: jpg 003.jpg (71.4 KB, 59 views)
File Type: jpg axles sand blasted 1.jpg (80.5 KB, 54 views)
File Type: jpg engine rebuild heads.jpg (59.8 KB, 52 views)
File Type: jpg engine rebuild heads 2.jpg (73.7 KB, 59 views)
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Last edited by Sirblissfull; 02-20-2012 at 14:27. Reason: Added pics of the upgrades before rebuilds were done
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Old 09-12-2011, 19:21   #3 (permalink)
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Place holder 2
Attached Images
File Type: jpg heads 2.jpg (75.9 KB, 34 views)
File Type: jpg heads 3.jpg (86.5 KB, 32 views)
File Type: jpg cylinders 1.jpg (86.5 KB, 39 views)
File Type: jpg engine parts 2.jpg (91.6 KB, 31 views)
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Last edited by Sirblissfull; 02-22-2012 at 00:18.
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Old 09-12-2011, 19:21   #4 (permalink)
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Old 09-12-2011, 19:22   #5 (permalink)
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Old 09-12-2011, 19:38   #6 (permalink)
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Nice pictures

I hate how that fiberglas insulation holds the moisture.
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Old 09-12-2011, 21:20   #7 (permalink)
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Cool.... I'll be looking for some ideas.
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Old 09-12-2011, 21:25   #8 (permalink)
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Nice Shane good to see these pics finally making a thread, I visted both your trucks at Area X and can't wait to see the progress done.

I still want one someday...

I also want a lot of things though...LOL
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Old 09-15-2011, 16:09   #9 (permalink)
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In. Going to be watching this one.
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Old 09-15-2011, 17:06   #10 (permalink)
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Cool
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