The Wall That Changed Our Van | DIY Partition Build | S2:E12

The partition wall wasn't just another woodworking project—it completely changed how our camper van functions. To install our Happijac bed lift, we first needed a rigid, perfectly square partition wall between the cab and the living space. That meant designing a structure strong enough to support future components while preserving driver comfort, visibility, storage, and access to the sliding door. Nothing about this build was straightforward. I walk through every measurement, template, design change, mistake, and rebuild as we create a custom partition wall for our 2024 Ram ProMaster 3500 159 EXT Super High Roof. Along the way you'll see why several ideas were abandoned, how the final design evolved, and the small details that make a huge difference in a van that has to survive years of travel. This episode covers: • Designing a full-height partition wall • Driver seat clearance and ergonomics • Structural mounting without modifying the B-pillar • Creating templates and scribing complex curves • Building overhead "pizza oven" storage supports • Planning electrical, lighting, and future service access • Marine adhesives, fasteners, and vibration prevention • Moisture protection and sealing plywood • Why iteration often produces a better final design Huge thanks to Tommy & Angie (Wayfaring Star / Sweet Dreams) and Jamie & Linda (Road Goat) for generously sharing photos, measurements, ideas, and countless conversations throughout this build. Their willingness to help made this project possible. Wayfaring Star Full Van Tour:    • Two time Best in show DIY VAN. SUPER HIGH ...   Products Used 3/4" UV Prefinished Maple Veneer Core Plywood https://www.menards.com/main/building... Link to MooseVan tools / materials / parts list: https://docs.google.com/spreadsheets/... Watch MooseVan from the beginning: Season One – The Budget Build Can two people and two dogs comfortably travel in a budget-built camper van? Follow the complete experiment from empty cargo van to our first real road trip.    • MooseVan: Empty Van to Off-Grid DIY Camper   Season Two – The Purpose-Built Build After proving van travel was the right fit, we started over. Follow the complete construction of our purpose-built 2024 Ram ProMaster Super High Roof camper van.    • MooseVan: Season Two   Designed through experience. Built with purpose. #MooseVan #CamperVan #VanConversion #DIYCamperVan #RamProMaster #OffGrid