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.
It Started as a Tired Old Cargo Van
Before any of the wild engineering began, this was just a high-mileage white Ford E350 cargo van—the kind of work vehicle you’d drive right past in a parking lot. A pair of small aftermarket side windows were about the only hint that someone had bigger plans for it. Starting with a humble, boxy cargo van is actually a smart move: the flat walls and long wheelbase give you a clean, predictable shell to build on, and the E350’s one-ton chassis is rated to carry the serious weight a build like this piles on.
Images via 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.
Images via President Chay on YouTube
With the roof gone, the team welded up a roll-cage-style steel skeleton to define the new upper level. This framework does the heavy lifting—literally—tying the new second story back into the van’s body so the whole structure stays rigid at highway speeds.
Images via President Chay on YouTube
Skinning the New Second Story
Once the steel cage was solid, the crew wrapped it in sheet metal, panel by panel, to create a weatherproof outer shell. The trickiest piece is the rounded front cap—the swooping, aerodynamic nose that helps the tall box slice through the wind instead of fighting it. Shaping flat metal into that smooth curve takes patience, a lot of careful trimming, and clean welds.
Images via President Chay on YouTube
Images via President Chay on YouTube
Out in the daylight, the bare-metal shell shows just how much volume the second story adds. What was a standard-height cargo van now stands tall enough to create a genuine upstairs.
Images via President Chay on YouTube
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.
Images via President Chay on YouTube
Inside, the payoff of building up becomes obvious. A raised platform creates a true upper level for sleeping, while the full-height space below becomes the main living area—two stacked zones in a footprint no longer than a regular van.
Images via President Chay on YouTube
Insulated, Wired and Plumbed for Real Living
Before any of the pretty finishes went in, the shell was sprayed with closed-cell foam insulation—a critical step in a metal box that would otherwise roast in summer and freeze in winter. The foam also adds a surprising amount of stiffness and quiets the road noise that plagues bare-metal vans.
Images via President Chay on YouTube
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—including a real wet bathroom, seen here taking shape with cement backer board and a freshly poured stone counter. 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.
Images via President Chay on YouTube
A Finished Interior That Feels Like a Tiny Home
The reveal is where this build stops looking like a van and starts looking like a small apartment. A black ladder leads up to the sleeping loft, recessed lighting runs the length of the ceiling, and a wood-and-tile galley with a full-size refrigerator lines one wall, ending at a solid green interior door.
Images via President Chay on YouTube
The kitchen punches well above its weight. Deep green shaker cabinets with brass pulls, a white subway-tile backsplash, a stone countertop, an under-mount sink, and glass-front upper cabinets give it a high-end residential look you almost never see in a vehicle this size.
Images via President Chay on YouTube
A Spa-Style Shower and Upstairs Sleeping Loft
One of the biggest surprises is the bathroom. Wrapped floor-to-ceiling in dark penny-round tile with a gold rainfall showerhead overhead, it feels more like a boutique hotel than a camper. Tiling a curved, moving wall like this is no small feat—every tile has to follow the contour while staying watertight against road vibration.
Images via President Chay on YouTube
Up top, the second story becomes a cozy sleeping berth. The curved ceiling hugs the mattress, and the elevated position keeps the bed completely separate from the living and cooking space below—the kind of privacy that’s almost impossible to get in a traditional single-floor van.
Images via President Chay on YouTube
Cooking and Living on the Road
With an induction cooktop, real counter space, and a full fridge, everyday meals happen the same way they would in a house—here, a quick batch of scrambled eggs on the glass cooktop. It’s a reminder that this rig was built to actually be lived in, not just filmed once and parked.
Images via President Chay on YouTube
Taking the Two-Story Van for a Drive
The real test of any vehicle build is whether it actually drives. Chay and family loaded up and took it out on the road, and the reinforced structure held together exactly as planned.
Images via President Chay on YouTube
From the back, you can see the practical touches that make it livable off-grid: a wall-mounted mini-split air conditioner, a rear roof rack, and a swing-out spare tire. From the side, the finished olive-green rig looks purposeful and surprisingly tidy for something carrying a whole extra floor.
Images via President Chay on YouTube
Images via President Chay on YouTube
On the move, the tall silhouette turns heads—proof that with enough welding, planning, and nerve, even a worn-out cargo van can become a one-of-a-kind two-story home on wheels.
Images via President Chay on YouTube
Watch the Full Build and Tour
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Alex