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A childhood Matchbox dream turned into a real Ford Econoline 4x4 campervan, and Jerry Bane walks through every detail of the build at Overland Expo East. This 1989 third-generation Ford van started life as a cargo van and was converted into a fully off-road capable overlanding rig with a Dana 60 front axle, Skyjacker suspension, BFG KM3 tires, and bead locks for airing down on the trail.

Inside, the layout is built for West Virginia’s low forest canopy, so nobody has to stand up. The swivel seats, propane stove, Dometic fridge, sink, Max Air fan, EcoFlow air conditioning, dual screens, and remote-work setup create a clever station-to-station camper van interior. Jerry also shows the rear swing-arm bumper, solar, shower system, storage, and the custom touches that make this vintage Ford feel personal.

It is a DIY camper van tour, off-road van build, and vintage 4x4 conversion story all in one, with travel miles from Maine to Baja, Mexico, and beyond. The best part is how the Freewheeling stripe package and square-body style connect the finished rig back to the Matchbox van Jerry loved as a kid.

Perfect for fans of camper van tours, Ford Econoline builds, DIY overlanding rigs, 4x4 van conversion videos, and vintage van life content. If you search for off-grid camper van ideas, overland Expo walk-throughs, or custom adventure van inspiration, this tour delivers a detailed look at a practical, trail-ready build.

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Travel
Transcript
00:00This is Patrick with New Jersey's Outdoor Adventures YouTube channel here at Overland East in Virginia.
00:05Just bumped into Jerry here. Jerry has a vintage Ford Econoline van that is fully off-road capable
00:12and he has a DIY camper build on the inside. And this thing is pretty cool.
00:16He's going to give us a tour inside and out, so join us.
00:21Hey, Patrick, how you doing? We're here at Overland Expo.
00:24My name is Jerry Bain and I'm going to take you around my Ford Econoline van.
00:28Let's start at the front.
00:30So the front bumper, we wanted an off-road look, so we went with a 1974 Warned Winch with the
00:37Evo.
00:39Underneath, we've got a Dana 60. This is a 92 Dana 60 on the front.
00:44And we're running, of course, we're running the BFG KM3 tires.
00:50We're also running the Trail Gear beadlocks because we do a lot of guiding in West Virginia
00:55and we do air down quite a bit.
00:57So while we're guiding and we're air down, we like that beadlock.
01:00Inside on the suspension, it's all Skyjacker.
01:03Guys, I'm going to tell you, Skyjacker suspension, we got with them a few years ago.
01:08We absolutely love it.
01:09We went with the Barnes four-wheel drive, hooked us up with some enduro joints and we had some custom
01:16suspension made in the front for that.
01:19We've put about 70,000 miles on this van in the last four years.
01:24So we have been to Maine, Canada a couple times.
01:29We've been to Baja, Mexico, of course, Pismo Beach, Los Angeles, Washington State.
01:36We went all the way down to Key West on one trip.
01:38We boogied down one side of the beach coast and came back up the other and we camped the whole
01:44time.
01:45Guys, we have KC's on the front, of course, and for a vintage build, you got Fuzzy Dice and the
01:51KC Lights.
01:52What else could you ask for?
01:53Over here on the right-hand side, we do use the WeBoost and we also have a CB and then
01:59we have a VHF for comps.
02:03So, let's move on back.
02:05So the van itself, we'll go ahead and walk you inside.
02:09So when we built the van, when we built the van in West Virginia, since we do a lot of
02:15guide work, West Virginia is all canopy.
02:19So we knew we couldn't do a high top, so we built the van inside specifically so you would never
02:24have to stand up.
02:25And what I mean by that is both front seats swivel and then we have a little propane stove right
02:31here in the front.
02:32So if I'm cooking, I'll be sitting in this seat cooking.
02:36Tina sits here, she preps, and then if you want to swing around there, of course, we have the Dometic
02:42refrigerator.
02:44And then right over here in the back corner is our sink.
02:47And if you want to go ahead and slide in there.
02:50So with our sink, let me go ahead and move this real quick.
02:54So that's our sink.
02:56So if you're going to brush your teeth or wash dishes, you'll just sit right here.
03:00So the way this van was designed, Patrick, is to never have to stand up.
03:03You just move from station to station to station.
03:06All right.
03:07We got the EcoFlow 12-volt air conditioning system.
03:12We've used this a lot.
03:13This thing works really good.
03:14This is the Wave 1.
03:15They now have the Wave 2 and the Wave 3 out, but we really like this one.
03:19Of course, we have the fan in the roof 99% of the time.
03:22With the Max Air Fan, guys, we never have to use the air conditioning.
03:27What else?
03:29Of course, we have 26-inch television.
03:31The van is set up with a MiFi set up.
03:34So when we're on the road, Patrick, we just stream whatever we're watching at home.
03:38And that works out real good for us as long as we have cell service.
03:41The van was originally built.
03:43We have the tables here.
03:44These are the Laguna mounts.
03:45Here and here, we didn't bring our tables with us.
03:48But this van is set up that my wife and I can both work remotely with dual screens.
03:53So that's always a plus.
03:55You got a couple of cabinets there that we put our stuff in.
03:58We got two cabinets above the stove.
04:01And then we did a custom backsplash.
04:04Got some sun chips and some chicken fritters.
04:08All right.
04:09So that's the basic inside of the van.
04:14If you want to walk around the back.
04:19So everybody knows you never have room for all your stuff.
04:21So last year, I built this rear bumper, dual swing arms.
04:27And what I didn't like was any, they only make, one company makes an aftermarket and it's just way too
04:33big.
04:33So when I designed this one, I built a backbone system behind it and then used the factory bumper as
04:39nothing more than a cover.
04:42We also have the entire camper set up.
04:45So if we are pulling into a campsite or whatever, we'll just plug in our umbilical cord and we'll hook
04:51up as normal.
04:53Up on top, we got 300 watts of solar if you want to get up there.
05:01We got 300 watts of solar on the roof.
05:03We use that to, of course, keep us charged up when we're down in Mexico or wherever.
05:08And then we built this custom rack on top as well to put, there is a fuel extra five-gallon
05:15mount.
05:16So on the back, we hung our spare tire and then, of course, our Blue Ridge Overland gear trash bag.
05:23We keep a cooler up here for extra water if we're on the road.
05:26This is our propane tank.
05:27We run power tank to air up and down.
05:30And this is for our shower.
05:31Let's go ahead and open it up.
05:35So I put the dual latches on here.
05:37So if a latch fails, it still won't open.
05:42So we did that.
05:43And then we also put the latch stop.
05:50Now, don't mind the dust because we've been on the road for five weekends straight.
05:55But this is the back.
05:59So back here is where we keep all the important stuff.
06:03Go ahead.
06:03So we have our Boss Base Camp shower system.
06:08So what's nice about that is, and then we have an extra couple of batteries there.
06:14What's nice about that is we keep everything here.
06:18So in the event that we need to shower like we will this weekend, we keep everything for our shower
06:26system in here, including an extra shower curtain.
06:28So the way the van is set up to shower is we'll hang that shower curtain between these two doors,
06:34and then you'll stand here and you'll go ahead and take a shower.
06:37And this shower curtain keeps that rain from getting or that water from getting inside.
06:41We keep our towels there on the back.
06:43We've got a little extra storage underneath.
06:47And that's the garage area.
06:50This is an awesome van, Jerry.
06:52I appreciate the opportunity to showcase it on the show.
06:54Now, it's a 1989, so they built these, what, from the 70s all the way to 91?
07:00Yeah, so this van specifically is considered a third-gen Econoline van.
07:05It was built from 1975 to 1991.
07:09In 1991, they went to the fourth-gen, and those are the more rounded ones that a lot of people
07:13use today.
07:14But this was the last generation of the square vans, and again, it was a long run.
07:21And they didn't come four-wheel drive new.
07:23This is a conversion, but there was a free-wheeling package.
07:27Oh, yeah, so this van specifically, I used to run a Comanche years ago, and my wife, our youngest son,
07:37went off to college at Marshall.
07:39So she started riding in the Comanche with me.
07:42If anybody knows the Cherokee or Comanche are real small.
07:44So I said, hey, you're going to keep running with me?
07:46She said, yeah, I think I will.
07:48I'm having fun.
07:49And I said, well, let's build something else.
07:51So I had this as a kid, as a Matchbox.
07:54It was this big.
07:55So Ford, from 1979 to 1981, this van specifically was considered the Ford freewheeling package.
08:04Now, the colors were a little more muted.
08:07I picked a little more vibrant of a color.
08:09But the stripe package was exactly like that.
08:11And as a kid, I thought, man, if I ever grow up, and if I ever can, I'd love this
08:17to be real.
08:17Just like anyone that played with the Matchbox.
08:19So the reason that this van looks the way it does, and why it's here getting ready to be backed
08:24into the BFG booth, is because we always wanted to build it.
08:28And I had a Matchbox as a kid that was just like this.
08:30So if you guys are down here this weekend, and you want to stop by and see us, we'll be
08:34at the BFG booth.
08:36That's Tina, and that's our little dog, Disco, right there.
08:38So if you get a chance, come and see us.
08:40We'd love to show you the van.
08:42I appreciate the opportunity.
08:44I came over, and I saw this van.
08:46I was like, oh, my God, this is incredible.
08:48I have a Ford Econoline camper van myself, and my viewers are very familiar with it.
08:53But not this body style.
08:55I have the newer rounded style.
08:56Yeah.
08:57And I can't believe there's like no rust on this thing.
08:59No, it's completely rust free.
09:02We found it as a cargo van in Lynchburg, just south of here.
09:06And a guy had it as a backup van for his electrical company.
09:10And we went ahead and came down and bought it, brought it home.
09:12It was just a little two-wheel drive van.
09:14We did the four-wheel drive conversion on it, because that's what we always wanted to do.
09:18And now we use it to lead groups through West Virginia.
09:23We do a lot of tour work in West Virginia, a lot of guide work.
09:25And again, we travel all over the country in it.
09:28What's the power plant?
09:29It's a 302 right now.
09:31But actually, we were talking coming up here.
09:33We've got a 351 coming.
09:36We're going to be moving up to a 351, because as you can tell, she's heavy.
09:40I'd say she comes in around 9,000 pounds.
09:43My van is an E350 with the V10 engine.
09:47That's a good one.
09:48It's 9,600 pounds.
09:49I'm 10-3.
09:50That's a good motor, though.
09:51I like that motor.
09:52It is.
09:53Seven miles a gallon.
09:54But it's strong.
09:55It's strong.
09:56Yeah.
09:56It's strong.
09:57I only get 10 with a 302.
09:59And I'm in the trucker lane on every hill.
10:02Well, this is awesome.
10:03I appreciate the opportunity.
10:04I wish you success here at Overland East.
10:08And maybe I'll see you down in Baja.
10:10Of course.
10:10All right.
10:11We'll see y'all.
10:12This is Baja from New Jersey's Outdoor Adventures YouTube channel.
10:14I'll see you next time.
10:16Bye.
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