This is my 2003 Chevy Express 3500, 1 ton van. It was a stock cargo van with a 6.0L engine when I got it.
I installed seat tracks and seat belts from an old Savana van and found three bench seats to match my interior. I then insulated with foam and finished out the interior with rubber matting from Tractor Supply and aluminum diamond plate for trim and the headliner.
I installed custom aluminum boxes by the wheel wells, a Topper roof rack from Inlad Trucking with a sheet of aluminum diamond plate on top of that, Larger BF Goodrich TA/KO LT265/75-R16 tires, front and rear hitch receivers, and custom front and rear bumpers.
I also installed a GM alarm system with the remote door lock clickers.
I installed 12,000lb milemarker hydraulic winches front and rear, with the wireless remotes. They run off the power steering pump.
I built a custom 35 gallon fuel tank that is mounted under the rear of the van and protected by a steel frame. it mounts where the spare tire had mounted. My fuel capacity is now 66 gallons. The spare is now up on the roof rack.
I also welded up a dual battery tray that mounts up under the left side near the drivers door. They are connected to the charging system with a Blue Sea battery Isolator system. These batteries power the 11,000 watt true sine wave inverter under the drivers seat for 110VAC and the Hella fog and driving lights mounted on the front brush guard. The whole system is charged by a 275 amp Load Boss alternator, monitored by a digital amp meter, and protected with a set of Blue Sea circuit breakers.
I also fabbed up a set of rock slider/step bars that are powder coated and bolted to the frame. You can actually jack up the van under those side bars.
I can now haul 11 people. It is great for going places when family comes to visit, camping, and is the perfect work van too!
Of course I have more to do to the van, a good project is never done!
If anyone is interested in hearing more, I started a group in "Yahoo Groups" for Express and Savana van owners to talk about their vans: http://autos.groups.yahoo.com/group/Express_Savana_vans/
The Express / Savana van group on "Yahoo Groups"

If you want to Email:
miltruckman@yahoo.com

I started a new Chevy Van discussion group on Yahoo.com There are lots of good links, photos, and documents.

Here is the address:
http://groups.yahoo.com/group/Express_Savana_vans/

everyone is welcome to come on over to talk about vans

Here is the Description:

This group is for those who own or are interested in Chevrolet Express or GMC Savana G body vans. For fans of GM (General Motors) or Chevy full size vans.
If you have any questions or tips on repair, customizing, accessories, towing, converting to a camper or conversion van, work truck, 4wd, AWD, or even a diesel engine. We would love to hear about it.
All discussions concerning your likes, dislikes, problems and experiences are welcome. Commercial advertising is not allowed. Please be courteous with your posts.

See you there,

Bill