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He Turned an Old Cargo Van into a 2-Story Tiny House!

on June 13, 2026

Most van builders try to squeeze every inch out of a single floor. President Chay went a completely different direction—straight up. Known for his extreme and technically demanding vehicle modifications, the YouTube builder took a tired old Ford E350 cargo van and turned it into something almost no one has attempted: a fully functional, two-story tiny home on wheels.

President Chay 2-Story Cargo Van Conversion
Image courtesy of President Chay on YouTube

Cutting the Roof Off to Build Up

The heart of this build is a dramatic structural change: cutting away the original metal roof of the Ford E350. Removing a vehicle’s roof sacrifices a lot of its rigidity, so Chay backed up the modification with extensive welding and heavy structural reinforcement before framing anything new. That reinforced shell is what made it possible to stack a second story on top while keeping the van road-worthy—effectively doubling the usable living space without adding a single inch to the footprint.

A Vertical Take on Van Life

By building up instead of out, Chay created a multi-level interior that feels far more like a small house than a typical camper van. Vertical space is usually the most wasted real estate in a van build, and here it’s been turned into distinct zones—living down below, sleeping up top. Pulling it off took an unusual blend of automotive mechanics, heavy-duty construction, and creative small-space design.

Wired and Plumbed for Real Living

Despite its unconventional, almost experimental look, this two-story van isn’t just a showpiece. It’s fully outfitted with complete electrical wiring for lights and appliances, plus plumbing for a working water system. It’s a reminder of just how far you can push a DIY conversion when you’re willing to rethink the rules of what a van can be.

Watch the Full Build and Tour

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Alex

Alex Pino is the founder of Tiny House Talk, a leading resource on tiny homes and simple living since 2009. He helps readers discover unique homes, connect with builders, and explore alternative living.
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