Getting Cool (cool food that is) Hack #4: Vanagon Refrigerator Upgrade

Love all the original bits of my Westy. She’s so pretty and so, so practical. But, I gotta gripe about the refrigerator. You can’t beat the practical nature of the original, vintage fridge. Off the grid on the propane that sucker will run for days, for weeks. But, here in Northern California (and much of North America) where temperatures in July and August are over 100-degrees, it just doesn’t do the trick. It will cool down about 40-degrees below the outside temps, but unless it’s 80-degrees or less, food isn’t kept cool enough to avoid spoiling. This means on most of our trips we use the fridge for storage and pack our cold-foods in an ice-chest, which then takes up space. And, space in the vanagon is a premium.

Since this is just how things are, a lot of people opt for the refrigerator elimination kit that you can buy at GoWesty. I mean it’s a cool alternative because it buys you some space in the cabinetry. But you still have a loss when it comes to packing around an ice chest. Some others opt for a portable refrigerator, which is basically like an ice-chest, so even if you gain space in the cabinets, you lose floor space. GoWesty makes some good arguments for why portable fridges are a good alternative to a horizontal replacement. But, Joe and I agreed we like that the vintage fridge is built-in and out-of-the way. And, we didn’t feel like we needed the extra cabinet space–after all–we’d rather go more minimal than have more space for crap we can live without.

So we opted for a modern replacement.

After some research into options, we found several people installing the T49 Truck Fridge. Van Cafe sells this refrigerator along with a trim kit. I found after taxes and shipping costs, it was most cost effective to buy it directly from the manufacturer. All told around $700. And, after watching a few install videos and reading other blogs we opted to make our own trim kit. I recently came upon this blog where the subject opted for a bigger version of the truck fridge, the T65. He does a good job in his three-part blog detailing the work he did to customize the cabinetry to work with the larger fridge. We didn’t feel confident ripping out big pieces of the cabinets and messing with the structure; plus projects like that seem to never get finished at my house, so we went with the T49 which just slips into the old refrigerator space with pretty minimal modification. I definitely surveyed the Samba Forum and any other blogs or videos I could find to get me started.

First step in this transition is removing the old refrigerator. Go Westy has a great video detailing how to remove the vintage fridge. And our fridge came out basically as easy as it the video explains. No surprises.

From here, we had to create a trim to go around the new T49. The old refrigerator was screwed into the cabinets on each side providing stability. The trim was built into the cabinet offering additional stability. Though bigger in cubic feet, the T49 is a bit narrower than the original it also has a front trim that must screw into a faceplate. Some of the blogs I came across suggested modifying the original trim for the new fridge. This makes it match and gives it a more built in feel. Since the original trim is part of the vintage fridge–which we hope someone will repurpose–we decided to make our own. We bought a 4 ft piece of plywood and used the original trim-piece to size the new faceplate. Then, we measured the opening (which are basically the dimensions of the back of the new fridge and cut an opening. There is a little cut out on the edge, which you could do easily with a router. Since we didn’t have one, Joe just used a chisel to notch it out.

We wanted the new plywood faceplate to match the original cabinetry even though very little of it will show because I am like that. One way to do this is to buy the laminate from GoWesty. Instead, I took the original fridge door to my local Sherwin Williams paint store and they matched paint to the laminate. It cost me about $6 for a tester quart of matching satin paint. After a couple of coats, I covered it with two coats of Deft clear-coat. Joe installed the frame with four L-brackets to keep it in place. As you can see the paint is a damn good match. The bottom of the refrigerator sits on top of four additional L-shaped brackets to keep it elevated off the ground. And, you’ll see that there is a space below the new fridge. Some people use this space to install a small propane heater. Some people leave as is for additional, quick storage. We plan to create a little hinged door for easy storage, but I am the type that like things to be behind closed doors and orderly, so that’s how it’s gonna be. I think it will make a great storage space for a griddle and a frying pan. Or we may store the inverter here. I saw one person make it into a cool wine cabinet. There are lots of options for how to finish this opening off in a quick Google Search.

In all the blogs and videos I watched on this install, there wasn’t much in the way of suggestions for wiring. What most people seem to do is connect it to their aux battery. The T49 comes with both a 110v and a 12v hook-up. The 110v plugs into the wall of the cabinetry just like the vintage fridge. This allows it to be powered by the hook-up if you’re fortunate enough to have one. Like others, we also hooked ours up to the aux battery. Joe wired a breaker and an on/off switch into the space where our aux battery is kept. This means that if the vanagon is parked in our driveway at home, we can switch off the refrigerator. No need to keep it running unless it’s being used. When we head out on a trip, we switch it on. When the car is driving, the battery is charged and the fridge is running. When we are parked, we can set out our solar panel during the day to keep the aux battery charged and the fridge running day and night. If we park to hike or kayak, we can put our solar panel in the front window and charge it while we are hanging out and having fun.

Once installed and screwed into the face place, this baby is good to go. As a final step, I’d like to use the GoWesty laminate on the front of the T49 to make it look as built in as possible. So, pictures of the all-the-way finished product to come. As well as my reviews of the new fridge. I hae to admit I am super stoked about the freezer in the T-49. I am excited to take my Trader Joe’s Vegetable Gyozas in the freezer for one of my favorite quick lunches. More to come…

Westfalia Custom Mattress Topper Hack #2

Anyone who loves their Westy probably tolerates the mattress. It’s not like it’s terrible, but that fold down seat in my 85′ is a little bumpy and hard in all the wrong places. I’ve been eyeing the GoWesty mattress topper for awhile, but it almost always seems to be sold out. What I really like is how it folds up nice and flat in the back of the van–taking up very little space, since space is a premium. And, I am not gonna lie. It’s also kinda on the pricey side for some foam…

My first attempt at the mattress issue was to find a trifold mattress I could use in it’s place. Basically, trifold mattresses don’t come in a size that fits. The measurements of the bed are 46″ x 72″ in the Westy. The closest thing is a full size 52.5″ x 73.5″. But, I don’t want extra hanging over the end or folding up on the sides. I already played that game with a big memory foam mattress topper that we would roll up in the back. It was HUGE. The twin size trifolds are also way too small, so no luck there.

Custom mattress topper extended.

Then I decided to make my own custom topper; I did. And, I love the heck out of it. I’ll tell you how I did it, and I will give you some suggestions to do it on the cheap. Well on the cheaper… at least.

Custom mattress folds up in the back of the van for easy storage.

I first went to the craft store where I was horrified to find that each piece of 2′ x 6′ foam is basically $80, and to make the trifold, I figured I would need 3 pieces. Sorry… not sorry… but f@#k that! That’s stupid. A whole mattress topper is only like 50-bucks for a regular bed. Ah… yes… A mattress topper is only 50-bucks. So, I immediately got on the target app and ordered a full-size 1.5″ foam mattress topper. Remember, overall the Westy mattress ain’t so bad, but just could use a little cushion. This mattress topper was $54 and some change with tax. Not bad. Since I was already at the fabric store, I went ahead and bought two pieces of canvas 60″ x 80″ (2.25 yards each). Honestly, I had the store cut two pieces just so I didn’t have to cut it at home. Lazy. I also bought two zippers. Each one was 28″ long. If I could have found a zipper that was 48″ or 50″, I would have bought it, but I couldn’t, and I wasn’t looking to special order something. Fabric and zippers and some thread all totaled about $60. So I’m about $104 dollars into this project. Not bad. Half the cost of the GoWesty mattress… that no one can buy anyways because the damn thing is always sold out.

Joe approves. I realize that in every hack picture he’s wearing the same outfit. He does have other clothes.

I have the most rudimentary sewing skills. I got a sewing machine I bought at a yard sale for $40. It’s a cheap Brother. Does the basic things. Basically, the mattress needs to be 46″ wide, and each side of the mattress is 1.5″ high and I estimated another .5″ for the seam on each side. So the total width was 50″. And, then I made the length 76″. That’s the 72″, plus 1.5″ for each side and .5″ on each side for the seam.

So basically you want fabric that is 50″ x 76″. And, yup. I just used two big pieces because like I said… my skills are rudimentary. And, I wasn’t about making some perfect slipcover with a 1.5″ edge all the way around. No. Freaking. Way.

From here, I sewed the zippers first. Because zippers suck. I don’t have a special zipper foot or other special tools; I just sewed the damn thing. In total, my two zippers are 56″ long. So I started in the middle of of the 50″ wide fabric that way the zippers meet in the middle and extend around the corners on each side by about 3-inches. I rounded the corners by bunching and pinning free-hand. Nothing special. Once those bitch-of-a-zippers were done. I basically just sewed it all the way around with those .5″ seams. Then I cut the foam down to 46″. And, My daughter helped me get the foam situated in the new slipcover. Pretty much… it’s rad. I love it. And, I am super-duper excited to try it out this weekend.

How would I do it cheaper? Well my friend just shared with me a farmhouse interior design hack. The article she sent showed someone who used paint drop-cloths to make canvas style farmhouse bedding on the cheap–you’re welcome for that extra hack. I was in too much of a hurry to be cheap. But this is the alternative I would have considered if I had thought it through more. Harbor Freight carries a 9′ x 12′ canvas drop-cloth for 16 dollars. This would be all your need for both sides of the slipcover.

So, $54 for the mattress topper from target, $10 for the zippers, and $16 for the drop-cloth. Grand total $80 if you’re a cheap-bastard who spends the time to think it through and has way more patience than I can manifest.

Overall, I am super pleased with the result, and I am exited about better sleep after a day of kayaking.

Update (2 hours later): I was cleaning up my mess which consisted of a strip of 7″ x 73.5″ foam and 10″ x 80″ strip of left over canvas. I got to wondering what can I do these scraps. And then I thought… ya know, I could make a couple of small pillows to go with the mattress. So I cut the 73.5″ piece of foam in half. And, I folded each half in half and sewed the foam pieces inside an old crappy pillow case. Really that step was just to keep the folded pieces together. Then, I used the left over canvas to make a couple of pillow cases. The pillows are about 3″ deep and make good little neck pillows. I tried them out. So, I’m happy that I used every bit of everything. And, everything is washable. And, I get a lot of the space I used to lose to big bulky bedding, pillows, and mattress toppers. Yay!

Maybe now, I just need to ask my sister-in-law for some iron on designs using her Cricut. Maybe a “mountains are calling…” or a cool forest symbol to liven things up. I’ll follow up if I do some fancy shit.