About The Race Rig Van Conversion
Tony, the founder of ORU, is an avid amateur mountain bike racer in southeast Wisconsin. He spent years traveling to races with his pickup truck, sleeping on the hard ground the night before races. When he traveled south to ride during the winter months, he was tired of spending money just to crash at a hotel for a few hours.
He most desired a comfortable, affordable place to sleep, a solid breakfast in the morning, and a safe place to store his expensive mountain bikes when traveling.
Tony realized a van build-out could solve all these problems. Eventually, Tony settled on a 2015 Ram ProMaster window van with a 159” wheelbase.
He spent 8 months thoroughly planning and designing his van, testing concepts and improving on them. He relied heavily on his skills in mechanical engineering, design, welding, technology (3-D scanning, 3-D printing, and CNC routing) to custom-fit his installations and be sure the van was well-sealed and well-insulated.
From this van build, Open Road Upfitters was born.
Outcome
The van has met all of Tony’s needs, and he could not be happier with the results.
Tony said, “In terms of the things I was after from a van, it’s perfect. I sleep well, it’s comfortable, and I can cook in it. It’s warm in the winter and cool at night in the summer. I can fit people when I need to.”
Required Features
Seating for 4 passengers to travel with friends
Interior storage for 4 mountain bikes
A fold-up bed for space versatility
30-gallon water capacity to wash bikes from the van
Seating for 4 passengers
Seating for 4 passengers was a difficult feature to accommodate. For starters, Tony had to meet the onerous but important specs of the Federal Motor Vehicle Safety Standards.
Further, the form and large size of the seats constrained the size and location of Tony’s kitchen and cabinetry, a compromise Tony was willing to make to travel with friends.
Despite the limitations, Tony still has ample space for a refrigerator, microwave, dishes, pots and pans, a 2-burner Coleman propane stove, a full-size griddle for his pre-race pancakes, and a Keurig coffee maker!
Interior storage for 4 bikes
Tony needed to fit four bikes in a 42-inch wide space. To solve this challenging task, Tony developed and fabricated a product he calls the Roll’N Rack (patent pending) to hold the bikes upright with the handlebars turned 90°.
a fold-up bed
Tony prioritized ample space for hauling bikes and gear, leading him to install a fold-up bed. This prevented Tony from installing permanent structures beneath the bed, such as a dining and work table.
In this picture, the mattress stands on its side while the bed platform is raised vertically (circled in green).
30-gallon capacity water tank
The 30-gallon water capacity required to wash bikes from the van contributed to a narrow allowance of space for the bikes. Tony came up with a creative solution in the Roll’N Rack.
Additional Features
Interior electric lighting and running water.
Electric heat supplied by shore power or a small gas generator, which costs only several dollars to keep the van at a comfortable temperature all night when traveling during winter.
Excellent air flow to cool the van in summer.
Custom cabinetry in kitchen.
1,135 square inches of countertop space.
Slide-out storage accessible from both the rear and the interior of the van. Sized specifically for luggage.
Head room for a 6-foot person to walk freely without bending. (Tony is 6’1” and has no issues.)
Full-size mattress.
A dog house for Tony’s 80-pound black lab, Jett.
A huge “garage” (76.5 cubic feet). When not storing bikes, Tony can fit his pop-up tent, a portable grill, a camp table, signage for Open Road Upfitters, and much more.
Window curtains.
Future additions: A removable cabinet for organization when Tony is hauling only two bikes, hot water, and a bench in the living area.