This is the working execution plan for the 2025 Ford Transit conversion. Use it to sequence decisions, purchases, fabrication, rough-in, finish work, and commissioning. Keep durable design choices on Decisions, dated work on Build Log, detailed technical notes on the system pages, and active buy items on Purchase Tracker.
The master unresolved-items tracker lives on Gaps and Questions.
Documentation-standardization review coverage and page-level sign-off live on Review Sign-Off.
The current van-specific MVP execution procedure lives on Van MVP Installation Instructions.
2025 Ford Transit high roof, extended body, AWD, 3.5L EcoBoost, 3.73 limited-slip, 9,500 lb GVWR.24V with a dedicated 12V subpanel and Victron as the preferred ecosystem.S&B 10-3017 spare-tire fresh tank, S&B 10-3015 passenger-side gray tank, and S&B 10-3016 driver-side urine tank.delivered - metadata incomplete, the Tetravan shower is still shipped - delivery proof missing, the Rixen MCS7 and floor kit are received, the Maxxfan is now installed - metadata incomplete, and the remaining Unaka roof-system / Fiamma / Starlink cluster is still mostly source-confirmed - receipt unknown with the Starlink roof mount still shipped - delivery proof missing. Keep exact order, shipment, delivery, receipt, and install state on Inventory and Purchases. The separate TNUTZ / 8020 structural direction is accepted elsewhere in the repo as the selected framing family, but current purchase-state proof for that material does not yet have a canonical inventory or source-record entry.This section defines the minimum-viable build order for making the van usable soonest. It is intentionally narrower than the full build plan: it prioritizes the systems needed for sleeping safely with CPAP power and for staying tolerable in heat.
| MVP Priority | Outcome | Why It Is MVP | Immediate Dependency Chain |
|---|---|---|---|
| 1. Electrical backbone for overnight CPAP use | House power that can run the CPAP overnight, recharge the house bank, and support normal charging needs. | CPAP power is the first non-negotiable use case. | Finalize bike tray concept -> finalize bed height -> close floor map / penetration schedule / real floor datum -> close rear electrical-bay package -> install batteries / protection / charging backbone -> connect fixed roof solar. |
| 2. Fixed charging inputs, including roof solar | Roof solar must be connected as part of the day-one charging strategy, alongside shore and alternator charging. | The van does not meet the power MVP if it can run loads once but cannot realistically recover energy. | Electrical backbone architecture fixed -> roof-zone integration map closed enough for wire entry / routing -> MPPT and protection hardware installed -> roof array landed and validated. |
| 3. Air conditioning | Install a working cooling system after the core power system is real enough to support it. | Comfort in heat is the second major user-defined requirement. | Electrical backbone live -> mini-split delivered-unit proof-plus-route bundle closes the remaining wire-gauge caveat on the already-exact branch package -> condenser/evaporator routing and mounts finalized -> AC branch and controls installed and tested. |
The current critical path is not buy inverter -> wire van. The real sequence is:
For planning purposes, the electrical MVP is the first-power package only, not the whole finished electrical build.
Included in the electrical MVP:
24V house bankMarinco 301EL-B -> Blue Sea 8077 -> MultiPlus -> Blue Sea 8027150/45 MPPT classCCP2Explicitly deferred from the electrical MVP:
60A plus local Blue Sea 7184 and 6 AWG minimum12V distribution service-face geometry, jumper cut lengths, and route-length-dependent branch closeoutProcurement consequence:
Requested Final-Branch-Schedule Audit, Exact-Field Gap Register, Objective Five-Field Matrix, Final-Branch-Schedule Completion Test, and Finish-Line Evidence Basis Register, because those owner-page sections now give the shortest field-by-field check of what is already exact, which single finish-line field still blocks each non-final row, how the explicit objective list maps onto device / fuse / wire / landing / package position, what still waits on physical proof, and how strong the current evidence is for each non-final row.8027 breaker allocation, direct-source C30 identity, or the premium-only front-node bus/protection method as remaining branch-definition blockers. Those requirement rows are exact now on the requirement itself, with the front node still open only on package-position capture. The direct-source completion split is narrower too: the C30 row is already closed, and the only remaining direct-source blocker is the mini-split's missing delivered-unit identity/current artifact. The still-open work is the seven named physical/proof captures and the downstream execution they unlock.GP29-31 bond landing, front premium-node package position, MultiPlus DC cable path, 301EL-B -> 8077 -> MultiPlus AC geometry, first-device GFCI/outlet layout, freezer route/service-loop/connector capture, and mini-split delivered-unit proof plus route capture.Treat the van as MVP-ready only when all of the following are true:
| Phase | Goal | Exit Criteria | Blocking Dependencies |
|---|---|---|---|
| 0. Baseline capture | Turn the van from a partially described platform into a measured, documented starting point. | VIN, final sale records, baseline photos, raw interior dimensions, roof measurements, and condition notes are recorded. | Access to van, tape/laser, camera, paperwork. |
| 1. Design lock | Freeze the major layout and systems architecture before drilling, wiring, or buying the remaining expensive parts. | Bed orientation/height, garage tray concept, rear driver-side battery tray plan, measured electrical-bay package closure, Rixen mechanical location, roof-zone integration map, three-tank underbody routing closure, cooling approach, and major electrical topology are decided. | Phase 0 measurements; open component research. |
| 2. Procurement closeout | Buy the remaining long-lead and architecture-defining parts. | Exact current Victron package directions are carried through the owner page and purchase tracker, sink and fridge are selected, the remaining dry-toilet integration hardware direction is closed against the current source-confirmed Nifty-NETTY kit baseline, and the still-held electrical rows are narrowed to named field captures or direct-source proof rather than left as broad architecture gaps. |
Phase 1 decisions. |
| 3. Shell and penetration prep | Prepare the van body and mounting points before systems go in. | All required body/roof/floor penetrations are planned, marked, and documented. | Phase 1 roof/floor/layout decisions; Rixen floor map; shower drain route. |
| 4. Mechanical and structural rough-in | Install the floor, roof hardware, structural framing, and major mounting surfaces. | Heated floor installed, rack/fan/roof penetrations done, primary framing strategy established, and critical mounting hardpoints are in place. | Phase 3 marking; confirmed floor no-drill map. |
| 5. Electrical rough-in | Build the power backbone before walls and cabinets close access. | Battery structure, grounding, main protection, conduits, roof solar entry, alternator-charge path, and branch routing are installed and documented, with the remaining release-for-build electrical holds reduced to the named landing-point, package-position, and wire-gauge captures on the owner page. | Phase 2 electrical procurement; Phase 4 structural mounts. |
| 6. Plumbing and hydronic rough-in | Install water storage, drain paths, pump/filter path, and Rixen integration. | Tank assignment, fill/vent/drain paths, sink/shower hot/cold lines, Rixen plumbing, shower drain, and service valves are installed and leak-test ready. | Phase 4 floor/structure; Phase 1 plumbing decisions. |
| 7. Interior buildout | Complete cabinets, bed, garage, finish floor, trim, and user-facing hardware. | Bed, galley, bike trays, trim, wall/ceiling finishes, and access panels are installed without losing serviceability. | Phases 5 and 6 rough-ins complete and photographed. |
| 8. Commissioning and documentation closeout | Prove the van works as a system and capture the final record. | Electrical, plumbing, heat, cooling, ventilation, and storage systems are tested; photos, labels, diagrams, and maintenance notes are complete. | All prior phases complete. |
Requested Final-Branch-Schedule Audit, Exact-Field Gap Register, Objective Five-Field Matrix, Final-Branch-Schedule Completion Test, and Finish-Line Evidence Basis Register before ordering cable, lugs, fuse gear, chargers, or the still-held HVAC branch package. In current owner-page terms that means landing point at the rear bond, package position at the front premium node and first-device GFCI / outlet package, and wire gauge on the MultiPlus, freezer, and mini-split rows.Decision-gate state lives on Gaps and Questions and the owner pages below. This table identifies the gates that affect sequencing; it should not carry a separate open / researching status that can drift.
| Decision Gate | Why It Must Be Resolved Early | Status Owner |
|---|---|---|
| Bed orientation and height | Controls garage volume, shower clearance, storage ergonomics, and bike tray design. | Gaps and Questions, Interior Layout, Measurements |
| Garage tray concept for two Velotric bikes | Controls bed height, garage usability, tie-down strategy, and tray-extension geometry. | Gaps and Questions, Interior Layout, Measurements |
| Rear driver-side battery tray, restraint, and extraction plan | Controls battery service access, local ventilation, restraint design, and the geometry available to the rest of the electrical bay. | Gaps and Questions, Electrical, Interior Layout |
| Measured electrical-bay package closure | Controls protection layout, cable exits, charger-combiner placement, and the final geometry of the rear driver-side electrical bay. | Gaps and Questions, Electrical, Interior Layout |
| Rixen mechanical location | Controls hose routing, vent routing, serviceability, and heat distribution. | Gaps and Questions, Climate and Insulation, Rixen Hydronic Heat and Floor |
| Three-tank underbody routing closure | Tank roles are now chosen, but final fresh fill/vent routing and urine vent/dump geometry still control plumbing runs, winterization, and underbody serviceability. | Gaps and Questions, Water and Plumbing, Interior Layout |
| Cooling approach | Controls electrical loads, ventilation, and interior space claims. | Gaps and Questions, Mini-Split Air Conditioner, Climate and Insulation |
| Roof-zone integration map | Controls solar layout, fan placement, Starlink strategy, lighting, and cable penetrations. | Gaps and Questions, Electrical, Climate and Insulation |
| Victron package finish-line closure | Controls wiring sizes, fuse gear, mounting space, purchase timing, and whether exact-current package rows are truly safe to order. | Gaps and Questions, Electrical, Purchase Tracker |
See Gaps and Questions for the master list. This page keeps only the phase structure and execution order.
These are the next tasks that should happen before more purchasing or fabrication:
| Task | Output | Related Page |
|---|---|---|
| Capture raw van dimensions | Measured interior/door/roof data | Measurements, Vehicle Profile |
| Photograph factory upfitter electrical hardware | Fuse panel location, outlet location, harness/interface photos | Electrical, Documents and Photos |
| Mock bed and bike storage envelope | Proposed bed height, tray length, bike clearances | Interior Layout, Measurements |
| Unpack and map Rixen floor | Exit routing, engraved heat-map photos, thickness confirmation | Climate and Insulation, Measurements |
| Close measured electrical-bay package and upgrade the one-line | Purchase-ready cabinet/protection layout plus updated engineered one-line inputs | Electrical, Gaps and Questions, Documents and Photos |
| Verify spare-tire fresh and driver-side urine routing | Confirm fresh fill/vent/pickup/drain logic plus urine hose/vent/dump packaging, with all tank-related floor/body penetrations resolved before installation | Water and Plumbing, Decisions, Interior Layout |
This is the recommended sequence for the current problem: a marked Rixen heated floor plus multiple underbody components and a small number of unavoidable penetrations.
This matrix separates true manufacturer-required penetrations from system-design penetrations that can often be moved, combined, or avoided.
| Component / System | Manufacturer Requirement | Penetration Type | Penetration Is Truly Required? | Notes |
|---|---|---|---|---|
| Rixen heated floor assembly | Rixen says the vehicle-specific precut fabricated floor kits are no cutting or drilling involved and use CNC-mapped overlay markings for the PEX and plates. |
Through the heated floor assembly itself | No new blind drilling into the floor assembly should be assumed. |
The floor kit itself should be treated as pre-routed and protected. The key coordination issue is choosing and documenting the built-in floor-loop exit routing, not creating new penetrations through the heated zones. |
| Rixen floor loop to MCS7 system | The current product page says the floor comes with all 5 options for heated floor plumbing exits to accommodate custom builds. |
Floor-loop exit routing | Yes, but use the built-in exit strategy rather than inventing new holes where possible. |
The actual exit path on your delivered floor needs to be documented from the physical panel markings and parts in hand. |
| Tetravan shower drain | Tetravan says the drain hole must be drilled through the floor directly underneath the center of the shower's gutter. | Floor drain penetration | Yes |
This is the clearest mandatory floor penetration in the current build. The downstream drain tube route then has to be coordinated under the van. |
| Tetravan hot/cold supply | Tetravan provides 1/2" NPS-F hot/cold connections. |
Water-line routing | Not necessarily through the floor |
These lines can usually be routed through the surrounding structure depending on layout. They are a plumbing requirement, but not automatically a floor-penetration requirement. |
| S&B undercarriage tank mounting | S&B sells these as undermount tanks with included brackets / hardware and fitment constraints. | Tank mounting | Not necessarily through the floor |
The tank mounting itself is underbody hardware work. The important unknown is whether any part of your chosen plumbing/wiring path must cross the van floor/body above the tank. |
| S&B tank venting | S&B/reseller guidance says the tanks are non-pressurized and must be vented. | Vent line routing | Yes, as a system path |
A vent path is required, but the exact penetration location is a design decision. This is one of the key things to sort out before the tanks go under the van. |
| S&B tank fill / pickup / drain / sender | Depends on how you assign the tanks and which ports you use. | Plumbing / wiring pass-throughs | Maybe |
These are real system penetrations if the chosen routing passes through the floor/body. They should be decided on the bench before the tank is installed. |
| 8020 structural anchors | User can move many anchors because the internal structure is modular. | Structural anchors | Usually no, unless a specific anchor truly must land there |
Most interior anchoring should be treated as flexible until proven otherwise. Move the structure to safe zones instead of forcing penetrations into bad locations. |
8020 interior structure to your advantage: move interior framing and anchor choices to suit safe zones wherever possible instead of forcing penetrations into bad locations.1 in / 25 mm maximum drilling depth around floor hazards.B / C / D pillar areas, roof bows, doors, fuel-tank area, brake-line area, and factory harness paths until the exact location is verified on the real van.Create the underbody equipment map
mounts to factory or supplied bracketsrequires a through-floor or through-body penetrationcan move because the 8020 structure is flexiblemust land in a very specific placeDry-fit and photograph the Rixen floor
Dry-fit the underbody components
Build a penetration schedule
Resolve the hard conflicts before drilling
8020 structure rather than forcing a risky floor penetration unless that anchor is truly non-negotiable.Mark and verify from both sides
Drill only the approved penetrations
Only then commit the floor and underbody hardware
This is the current source-backed working schedule for shell penetrations that still matter to the van build: floor, roof, rear-door, wall, and body-panel openings or pass-throughs. It is not fully field-closed yet. Use it as the canonical pre-drill table and keep unknown fields explicit until the real van and delivered components close them.
Legend:
Required = the current design or manufacturer evidence says this path needs a real shell penetration.Built-in exit = the path exists through the delivered floor-system design and should be documented, not invented with a new blind hole.Not currently planned = the active design currently avoids a shell penetration for that path.Deferred = documented future-direction penetration, but intentionally not a current drill item.| ID | Path / system | Current penetration state | Source-backed current direction | Current raw hole size basis | Interior / mounting-side constraint | Exterior / opposite-side constraint | What is still open before drilling |
|---|---|---|---|---|---|---|---|
FP-01 |
Rixen heated-floor PEX exit to plumbing bay | Built-in exit | Use the floor's built-in aft passenger-side exit into the plumbing area; do not invent a new hole through the heated field. | No new raw hole size should be assumed for the floor assembly itself. | Preserve the floor no-drill map and leave the Columbia/JRD-required 2 ft excess 3/8 in PEX at the exit. |
Confirm the exit lands cleanly into the passenger-side plumbing/service area without conflicting with other nearby penetrations or mounts. | Physical delivered-floor exit confirmation, exact local routing, and the final no-drill / safe-anchor map. |
FP-02 |
Tetravan shower drain | Required | Tetravan requires a direct floor penetration under the center of the shower gutter into the downstream gray-side drain path. | 2.375 in through-floor hole with the top 0.375 in to 0.75 in enlarged to 3.125 in per the support-emailed install instructions. If there is no plywood subfloor at that location, Tetravan says the 3.125 in diameter may need to continue through the full thickness instead of only the top layer. |
Must clear heated-floor tubing and any floor no-drill zones. | Must clear underbody structure and support the downstream drain-tube route to the gray side. | Exact location from a datum, final no-drill reconciliation, and final underbody route closure. |
FP-03 |
Fresh pressure-fill line to spare-tire fresh tank | Required in current tank architecture | Current working tank plan uses one floor/body penetration for the 1/2 in ID pressure-fill line from the city-water inlet branch to the fresh tank upper 1/2 in port. |
No exact raw hole size is currently closed from purchased grommet stock. The purchased GHG-AST assortment tops out at 3/4 in ID, the purchased Hillman 881262 is 23/32 in ID in a 1-1/8 in OD body, and the purchased Unique Bargains S26032300UX4620 is 1 in ID / 30 mm hole and therefore oversized for this 7/8 in-class hose. |
Keep clear of the floor heat map and future interior service panels. | Keep clear of crossmembers, exhaust heat, brake/fuel lines, and the selected fresh-tank routing path. | Exact body/floor crossing point, final route after real tank mockup, and the actual pass-through hardware choice if this path is meant to stay truly grommeted. |
FP-04 |
Fresh pickup line from spare-tire fresh tank | Required in current tank architecture | Current working tank plan assumes one penetration for the fresh pickup line rising from the selected passenger-side low 1/2 in tank port into the interior plumbing area. |
No exact raw hole size is currently closed from purchased grommet stock for the same reason as FP-03: the current purchased grommets do not provide a clean 7/8 in-class hose match. |
Must coexist with the floor map and nearby interior plumbing concentration area. | Must clear the spare-tire tank, brackets, and underbody routing hazards. | Exact location, grouped-versus-separate routing with other service lines, and the actual pass-through hardware choice if this path is meant to stay truly grommeted. |
FP-05 |
Gray inlet trunk from shower/sink side to gray tank | Required in current tank architecture | Current working tank plan assumes one penetration for the 1-1/2 in gray inlet trunk into the gray tank top 1-1/2 in inlet. |
No purchased grommet match is currently documented for the selected 1.90 in OD gray hose family. The prior 2-3/8 in recommended opening (2-1/4 in bare minimum) remains only a working edge-protection / sealant opening, not a purchased grommet-backed hole size. |
Must not conflict with heated-floor tubing, shower drain path, or floor-adjacent anchors. | Must clear the passenger-side gray tank, dump hardware, and underbody interference. | Exact location, final relationship between the Tetravan drain path and the combined gray inlet route, and the final pass-through hardware strategy. |
FP-06 |
Urine hose from sliding toilet to driver-side urine tank | Required in current tank architecture | Current working tank plan assumes one penetration for the 0.75 in ID urine hose from the sliding toilet to the driver-side urine tank inlet. |
Use the purchased Unique Bargains S26032300UX4620 top-hat silicone grommet: 25 mm / 1 in ID grommet in a 30 mm / 1-3/16 in drill hole. |
Must support the guided slope-controlled hose path and avoid floor heat / anchor conflicts. | Must clear the driver-side urine tank routing and avoid sag-prone or damage-prone underside geometry. | Exact hole location, final slider-loop geometry, and support-clamp pattern. |
FP-07 |
Shared sender / heat-pad wiring bundle for tanks | Required if tank wiring is brought inside as one grouped service bundle | Current working tank plan assumes one protected grouped penetration for tank sender and heat-pad wiring, and the user has now stated that the raw wires only need about 1/4 in before loom and that the bundle should be loomed before the pass-through. |
Use Alex Tech 1/4 in split wire loom tubing, Amazon ASIN B07TDGMDW4, on the grouped sender / heat-pad bundle and land it in the purchased Gardner Bender GHG-AST 1/2 in ID grommet. The resulting drill hole is 11/16 in. The purchased 3/8 in grommet is too tight for the typical outside diameter of 1/4 in split loom. |
Keep clear of floor tubing and avoid crowding adjacent plumbing penetrations. | Keep clear of spray, abrasion, and tank service-drop movement; preserve service loop for lowering tanks. | Exact bundle path, exact connector/disconnect mounting, and final delivered receipt state for the selected loom. |
FP-08 |
Fresh vent | Not currently planned | Active design keeps the fresh vent as an all-underbody high loop with a protected exterior outlet rather than a floor penetration. | 1 in only if the design later changes and a penetration becomes necessary. |
No floor penetration should be created for this path under the current plan. | Maintain the protected downward-facing outlet and avoid water-trap geometry. | Final exterior outlet placement and high-loop confirmation. |
FP-09 |
Gray vent | Not currently planned | Active design keeps the gray vent as an all-underbody high loop with a protected exterior outlet rather than a floor penetration. | 1 in only if the design later changes and a penetration becomes necessary. |
No floor penetration should be created for this path under the current plan. | Maintain the protected outlet and avoid conflict with dump hardware and spray zones. | Final exterior outlet placement. |
FP-10 |
Urine vent | Not currently planned | Active design keeps the urine vent as an all-underbody high loop with a protected exterior outlet rather than a floor penetration. | 1 in only if the design later changes and a penetration becomes necessary. |
No floor penetration should be created for this path under the current plan. | Keep segregated from gray-service areas and choose an odor-aware protected outlet position. | Final exterior outlet placement and rinse-workflow coexistence. |
FP-11 |
Fresh tank drain / gray dump / urine dump service paths | Not currently planned | Current tank service hardware is intentionally underbody-facing and should not require new floor penetrations under the active architecture. | No floor/body hole currently planned. | Do not create an interior penetration just to service a path that is already designed to stay underbody. | Preserve access to dump/drain valves and hose-connection points from below. | Final underbody access proof after tank placement. |
FP-12 |
Floor-adjacent structural anchors that truly must cross the floor/body | Conditional only | Most interior anchors should move to safe zones instead of forcing a floor penetration; only anchors that remain genuinely non-negotiable belong on this schedule. | No generic raw hole size should be assigned. | Must respect the documented heated-floor no-drill / safe-anchor map. | Must clear underbody structure and any nearby system routes before approval. | The actual list of non-movable anchors after the floor map and interior framing plan are physically reconciled. |
BP-01 |
City-water inlet body-panel cutout | Required in current fresh-water architecture | Current preferred exterior interface is JR Products 37262145 on the aft passenger-side body panel as the single hose-connected city-water inlet. The current user-confirmed architecture splits the inlet immediately inside the van so one branch can feed the cold manifold directly and the other branch can pass through the floor to fill the fresh tank in the aft passenger-side floor zone. Official JR product pages currently prove the cutout, outside diameter, valve depth, check valve, and dust cap, but do not currently prove an included mounting gasket. JR also separately sells hatch/install kits with screws and butyl tape, so do not assume the inlet package itself closes the sealing stack until the actual package or stronger JR install material proves it. |
1-1/2 in cutout from Water and Plumbing. |
Keep high enough and serviceable on the aft passenger-side body panel, consistent with the current selector/split package and the accepted tank-fill branch direction. | Must clear exterior trim, internal structure, and the final regulator/selector package plus the fresh-tank fill branch route. | Exact body-panel location, final internal route from inlet to selector/regulator path, and final body-side sealing stack if the package-included gasket is not physically present. |
BP-02 |
Shore-power inlet body cutout | Required in current electrical MVP architecture | Marinco 301EL-B is the current exact shore inlet on the driver-side rear utility zone. User physical direction now keeps the inlet immediately behind the backer with the 8077 close to the MultiPlus and the total AC path within about 5 ft, so this row is no longer open on broad route architecture. Current official Marinco inlet instructions explicitly call for positioning the supplied mounting gasket under the inlet at install time, so the inlet package itself now closes the base gasket layer. |
2-7/8 in main body cutout plus 1/8 in pilot holes for the four mounting screws from Electrical. |
Keep immediately behind / adjacent to the rear backer utility zone so the 8077 and MultiPlus feeder stay in the accepted short-run package. |
Must clear the rear utility-wall cavity, permit weather sealing, and preserve inlet serviceability and feeder bend radius. | Exact final inlet offset, fastener pattern transfer, and ordinary install-time sweep / service-slack execution inside the accepted short local path. |
BP-03 |
Rixen passenger-side hydronic hose pass-through zone PT-G1 / PT-G2 |
Required in current Rixen architecture | Current Rixen plan requires two protected passenger-side service-bay penetrations for 3/4 in glycol hose: one supply to the underbody furnace and one return back into the service bay. The user has now provided a physical outer-hose measurement of about 26 mm, and Gmail Amazon order recovery now proves the ordered bulkhead family is Enoch's Land 3/4 in hose-barb thru-bulk fitting B0C1MXFRPJ, quantity 2, order 112-5934257-2733820. |
Standard-grommet direction is superseded by the ordered 3/4 in bulkhead fittings, but the exact raw hole size is still not closed because the delivered pass-through body/cutout dimension has not yet been measured or recovered from a trustworthy spec. |
Preserve bend radius, strain relief, sealing, and the gravity-fed pump relationship in the service bay. | Must clear frame structure, fuel/brake lines, wheel-spray zones, exhaust heat, and gray-water hardware. | Exact pass-through positions and the delivered bulkhead-body / cutout basis before drilling. |
BP-04 |
Mini-split refrigerant / power / control pass-through | Conditional only | Current preferred cooling direction is a reinforced/gasketed pass-through for the pre-terminated hose/cable bundle, but the final route is still unresolved between passenger rear door and a lower fixed-body/floor path. | No final raw hole size is closed because the architecture is still open; current measured bundle basis is 28.5 mm max larger-fitting OD, 24 mm larger-hose OD, 24 mm smaller-fitting OD, 19 mm smaller-hose OD, 18 mm power loom, and 7-11 mm control bundle/loom. |
Keep clear of latch rods, lock hardware, hinge reinforcement, window/door structure, and preserve service access with a real sealed pass-through assembly rather than loose sealant. | If door-mounted, treat the door as a wet cavity and preserve a deliberate flex loop to the fixed body; if fixed-body / lower-wall, preserve refrigerant bend radius and protected routing. | Final route choice, final pass-through hardware family, final hole count, and proof that the manufacturer/manual evidence allows the chosen line-motion geometry. |
BP-05 |
Mini-split condensate shell exit | Conditional only | Current preferred cooling direction is a fixed gravity drain down a fixed interior/body-side chase rather than draining through the moving rear door, unless the actual unit forces another path. Current selected replacement hose direction is Eastman 98570, 5/8 in ID x 3/4 in OD, because the user measured the indoor-unit drain spout at about 14.5 mm OD and the provided 5 ft hose as insufficient. Gmail Amazon order recovery now also proves the user ordered Enoch's Land 5/8 in hose-barb thru-bulk bulkhead fitting B0C1MWXKFB, order 112-5220671-3368217, as the preferred pass-through concept. |
Grommet-only direction is no longer the primary plan. The exact raw hole size is still not closed until the delivered 5/8 in bulkhead body/cutout dimension is measured or otherwise recovered from a trustworthy spec. |
Must preserve gravity fall from the high indoor unit and remain serviceable for drain inspection/cleaning. | Must discharge in a protected location that does not wet critical hardware or route into a moving-door cavity unless forced by the unit. | Final condensate exit location and the delivered bulkhead-body / cutout basis before drilling. |
BP-06 |
Portable-solar exterior inlet | Deferred | Electrical owner page still reserves an exterior portable-solar inlet near the driver-side shore-power zone as a later-phase add-on. | No exact cutout basis yet because inlet hardware is not selected. | Reserve route, labels, and access, but do not drill this as part of the current build phase. | Keep grouped with exterior utility plug-in paths if it is added later. | Final connector hardware, final cutout, and actual portable-array package closure. |
RP-01 |
Roof entry cluster for fixed roof solar and future roof-zone cables | Required in current electrical architecture | Current accepted direction is one serviceable roof-entry cluster using a roof-mounted junction box over a single shared roof penetration. | One roof opening in the roughly 2-3 in diameter class from Electrical and Decisions. |
Land above the driver-side roof/center service zone with room for strain relief, service loops, and future cable additions. | Must clear solar mounts, ladder/use zones, fan area, and maintain lid/gland serviceability after installation. | Exact roof location, final day-one cable count, exact central-hole size, and final gland mix before drilling. |
RP-02 |
Maxxfan roof opening | Installed | User reports the Maxxfan roof penetration and fan install are already complete. Maxxair's official Maxxfan Deluxe install manual remains the source for the standard opening and install method, but this row is no longer a pending drill item. | 14 in x 14 in roof opening from the official Maxxfan Deluxe install manual. |
Preserve the installed garnish / ceiling-thickness fit and wire-entry accessibility for final electrical hookup. | Maintain the existing roof sealing stack and verify it continues to clear nearby rack/solar hardware and service access. | Roof penetration no longer open. Remaining work is electrical hookup, branch protection, and any installed-condition photo / inspection capture. |
This is the simpler floor-focused table for the tank / hydronic / condensate paths. It is the best current answer to "which purchased pass-through hardware gets used and what hole size is actually source-closed from that hardware." If a row says the cutout is still not yet re-closed after delivered bulkhead-body / cutout measurement, do not drill from nominal fitting size alone.
| Outside component | Inside component | Item passing through | Item OD / size | Purchased pass-through hardware to use | Hole size from that hardware | Hole location |
|---|---|---|---|---|---|---|
| Rixen / Eberspaecher underbody furnace | interior hydronic service bay | glycol supply hose via PT-G1 |
about 26 mm OD from the user's physical glycol-hose measurement |
Use the ordered Enoch's Land 3/4 in hose-barb thru-bulk bulkhead fitting, ASIN B0C1MXFRPJ, from Amazon order 112-5934257-2733820. |
not yet re-closed after delivered bulkhead-body / cutout measurement | Current coarse area guess: aft of the passenger wheel well. Passenger-side service-bay pass-through zone. |
| Rixen / Eberspaecher underbody furnace + Rixen fuel pump | Rixen MCS7 control / power box in the interior hydronic service bay | shared furnace and fuel-pump power/control harness crossing | about 12 mm OD from the user's physical harness measurement before loom; current selected protection sleeve is Alex Tech 1/2 in split wire loom tubing, Amazon ASIN B0CLLD8JKR, now supported by Amazon order 112-3672013-5534621 |
Current exact grommet/hole are not yet re-closed from the finished loomed OD. Use the selected Alex Tech 1/2 in split loom around the measured shared Rixen harness, then measure the actual finished crossing OD and choose the grommet from that installed size instead of assuming the old bare-harness fit remains valid. |
not yet re-closed after loom selection | Current coarse area guess: aft of the passenger wheel well. Shared service-bay wiring pass-through zone for the furnace and pump harnesses, coordinated with the furnace-side hydronic routing and protected from wheel spray, exhaust heat, and abrasion. |
| Rixen engine-heat plate exchanger loop | interior hydronic service bay | glycol return hose via PT-G2 |
about 26 mm OD from the user's physical glycol-hose measurement |
Use the ordered Enoch's Land 3/4 in hose-barb thru-bulk bulkhead fitting, ASIN B0C1MXFRPJ, from Amazon order 112-5934257-2733820. |
not yet re-closed after delivered bulkhead-body / cutout measurement | Current coarse area guess: aft of the passenger wheel well. Passenger-side service-bay pass-through zone. |
S&B 10-3015 passenger-side gray tank |
sink | gray inlet hose / trunk | 1.90 in OD from the on-hand UDP T30006005 hose family |
Use the ordered Outus 1.5 in PVC bulkhead fitting, ASIN B08SJW2CMV, together with the ordered 2 Pack 1436 Series PVC Tube Fitting 1-1/2 in adapters, ASIN B0FNCG43TG. |
not yet re-closed after delivered bulkhead-body / cutout measurement | Current coarse area guess: forward of the passenger wheel well. Exact location still open; passenger-side gray-tank inlet area. |
S&B 10-3015 passenger-side gray tank |
sender / heat-pad wiring | protected tank wiring bundle | about 1/4 in raw wires before loom; selected Alex Tech 1/4 in ID split-loom bundle |
Use the purchased Gardner Bender GHG-AST 1/2 in ID grommet around the selected Alex Tech 1/4 in split-loom bundle. Two GHG-AST packs are currently recorded in inventory. |
11/16 in |
Current coarse area guess: forward of the passenger wheel well. Exact location still open; grouped tank-service wiring penetration if one shared bundle is used. |
S&B 10-3017 spare-tire fresh tank |
city-water fill / selector branch | fresh pressure-fill hose | 7/8 in OD from the delivered Flair-It FL57FR hose family |
Preferred current hardware is the ordered Fitvell stainless-steel 1/2 in hose-barb bulkhead fitting, ASIN B0B718JHKH, from Amazon order 112-6979735-4197808. The ordered suiwotin 7/8 in ID / 1 in drill hole grommet pack, ASIN B0DRCM5T5F, is preserved as alternate/fallback stock rather than the primary plan. |
not yet re-closed after delivered bulkhead-body / cutout measurement | Current coarse area guess: aft of the passenger wheel well. Exact floor/body crossing point still open; route down to the tank upper 1/2 in port without crossing floor-heat no-drill zones. |
S&B 10-3017 spare-tire fresh tank |
pump / strainer area | fresh pickup hose | 7/8 in OD from the delivered Flair-It FL57FR hose family |
Preferred current hardware is the ordered Fitvell stainless-steel 1/2 in hose-barb bulkhead fitting, ASIN B0B718JHKH, from Amazon order 112-6979735-4197808. The ordered suiwotin 7/8 in ID / 1 in drill hole grommet pack, ASIN B0DRCM5T5F, is preserved as alternate/fallback stock rather than the primary plan. |
not yet re-closed after delivered bulkhead-body / cutout measurement | Current coarse area guess: centerline where the shower is, with aft of the passenger wheel well as the main alternate until the exact tank-side rise point is captured. Exact location still open; route up from the selected passenger-side low 1/2 in tank port into the interior plumbing area. |
S&B 10-3017 spare-tire fresh tank |
sender / heat-pad wiring | protected tank wiring bundle | about 1/4 in raw wires before loom; selected Alex Tech 1/4 in ID split-loom bundle |
Use the purchased Gardner Bender GHG-AST 1/2 in ID grommet around the selected Alex Tech 1/4 in split-loom bundle. Two GHG-AST packs are currently recorded in inventory. |
11/16 in |
Current coarse area guess: centerline where the shower is. Exact location still open; grouped tank-service wiring penetration if one shared bundle is used. |
S&B 10-3015 passenger-side gray tank |
Tetravan folding shower | shower drain fitting / drain opening | Tetravan drain path, downstream 1-1/2 in threaded hookup |
No grommet used here. Use the Tetravan drain opening geometry from the support-supplied install instructions. | 2.375 in through-floor, with the top 0.375 in to 0.75 in enlarged to 3.125 in |
Current coarse area guess: centerline where the shower is. Directly under the center of the Tetravan shower gutter. |
| exterior condensate discharge point | mini-split indoor unit | condensate drain hose | selected 5/8 in ID x 3/4 in OD hose class; Amazon order 112-3672013-5534621 now supports Eastman 98570 |
Preferred current hardware is the ordered Enoch's Land 5/8 in hose-barb thru-bulk bulkhead fitting, ASIN B0C1MWXKFB, from Amazon order 112-5220671-3368217. The on-hand Gardner Bender GHG-AST 3/4 in grommet remains a fallback path rather than the primary plan. |
not yet re-closed after delivered bulkhead-body / cutout measurement | Current coarse area guess: aft of the passenger wheel well. Exact location still open; current preferred direction is a fixed gravity drain down a fixed interior/body-side chase. |
S&B 10-3016 driver-side urine tank |
sliding toilet | urine hose | 1 in OD from the delivered EZ-FLO 98624 hose |
Use the purchased Unique Bargains S26032300UX4620 top-hat silicone grommet. Lowe's order 300901141260552832 and the seller listing both identify it as 25 mm / 1 in ID with a 30 mm / 1-3/16 in drill hole, and the user later confirmed the physical on-hand pack is the white 7-pack measuring about 1 in ID and 1.2 in OD at the body/lip. |
30 mm / 1-3/16 in |
Current coarse area guess: forward of the driver wheel well. Exact location still open; route to the driver-side urine-tank inlet while preserving the slider loop and slope. |
S&B 10-3016 driver-side urine tank |
sender / heat-pad wiring | protected tank wiring bundle | about 1/4 in raw wires before loom; selected Alex Tech 1/4 in ID split-loom bundle |
Use the purchased Gardner Bender GHG-AST 1/2 in ID grommet around the selected Alex Tech 1/4 in split-loom bundle. Two GHG-AST packs are currently recorded in inventory. |
11/16 in |
Current coarse area guess: forward of the driver wheel well. Exact location still open; grouped tank-service wiring penetration if one shared bundle is used. |
not planned path changes direction and now needs a penetration, add or revise the row before drilling.8020 system gives you freedom to re-place rails and tie-ins.If a hole affects any two of these at once, it belongs in the coordinated penetration schedule before work starts:
Nifty-NETTY kit baseline, pump, filter, plumbing valves/fittings, and electrical protection/distribution hardware.12V subpanel conversion path.The project is considered documentation-complete when:
2026-05-17.2026-05-22 so critical decision gates point to status owner pages instead of carrying duplicate open / researching state.