Here at bloK Pod, we're all about bringing dreams to life, especially when those dreams involve hitting the open road in a custom-built adventure vehicle. Between us, my business partner, Dave Thompson and I have 60 years of engineering experience, and thrive on the challenge of turning a client's vision into a reality.

We’ve learned a lot together: producing e-bikes before most people had even heard of them; building arms for computers, churning out 3,500 a week; and working in movies, creating props for use on both sides of the camera.

All this was great experience for when we first turned our hands to van conversions about eight years ago.

The journey starts with a brief from the client. Sometimes they are detailed, sometimes not. But everything starts with a plan. It’s how we figure out what is possible, what will work and what might just be a bridge too far, at least depending on the available budget. We love to over-deliver, and that means meticulously planning every detail.

Find out what the Hardest Geezer thought of the Hardest Wagon

When we set out to build a van for the Hardest Geezer, Russ came to us with a wish list, and our job was to make it happen. He wanted a sleeping area, lots of power, ample storage, a cooking area, water transport capabilities, a shower, if possible, the ability to stand up inside, and an awning. He wanted a TV and outdoor lighting. Oh. And he wanted an ice bath.

Power is always a big consideration. Everything had to be smart-power and smart-appliance compatible, and our solution included a tailor-made plug-and-play system to support this.

We delivered everything he wanted, and a few extras besides. There's a slide-out table, built-in storage, a cooking area, a slide-out toilet, and a slide-out wardrobe next to the beds. We included little cubby holes, individual touch-controlled lighting, reading lights, and USB ports. As well as the TV, there's a microphone and amplifier, a six-speaker outdoor system, and a touchscreen for all power controls. We also fitted air conditioning and a heater, and a 55-litre fridge-freezer with a built-in battery.

At the back, we incorporated two sliding trays, each capable of holding 200 kilograms, along with side storage. The cockpit is pretty much standard, but we added some security features to help protect the contents when Russ is travelling.

I even tested the boiler for Russ's van at my home when my regular one packed up! It’s that dedication, combined with high-quality components, that makes a bloK Pod van special. The result is a Ford E-Transit ¹ that’s as tough and as versatile as the man who will be using it on his next adventure.

The planning for the build alone took eight to nine weeks. Then, sourcing all the parts took about a week and building the van, up against a super-tight deadline, was two weeks of long days and late nights. Fortunately, the real hard work was already done. Planning is the key. Of course, there’s always a curveball. For this project, it was the addition of a third bed. But we planned, we tested and we made it work.

What makes all the hard work most rewarding is the look on our clients’ faces when we unveil the finished conversion. This was no exception. Russ just had this incredible broad grin, and I could only imagine the fantastic use he will be putting the Hardest Wagon to.

Happy adventuring Russ!

Dan Lindfield runs bloK Pod with his partner Dave Thompson

¹Up to 402 km driving range based on full charge of E-Transit with enhanced range option. Estimated range using Worldwide Harmonised Light Vehicle Test Procedure (WLTP). Figures shown are for comparability purposes and should only be compared with other vehicles tested to the same technical procedures. The actual range may vary due to various factors (e.g. weather conditions, driving style, route profile, vehicle condition, age and condition of the lithium-ion battery).