Food Truck Build 1979 P60

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BelCibo
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Food Truck Build 1979 P60 - Sat, 12/22/12 1:27 PM
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[Helpful answer received] / [List Solutions Only]
Our journey has started and thought we should share our project as so much information from this forum has inspired us.
 
The business name is "Bel Cibo" which means beautiful food in Italian.  My wife, Italian heritage, will be running the business with a planned opening date of April 2013.  The truck will specialize is gourmet style sandwiches and soups that will be served during lunches on weekdays, Saturday nights, and the occasional special event.
 
Logo, work in progress.  The pan is a little goofy and needs some work but you get the idea. 
 
The truck is a 1979 Grumman P60.  It was being converted into a food truck when we purchased it from the owner.  It had been gutted, steel tubing studs on the drivers side, a small window installed, and fresh paint.
 


 
After removal of steel studs

 

<message edited by BelCibo on Sun, 12/23/12 10:02 AM>

BelCibo
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Re:Food Truck Build 1979 P60 - Sat, 12/22/12 1:41 PM
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Purchased 2 x 2 x 1/8" 19' long 6063 aluminum channel and installed on 2' centers.  $46 each.  Attached them with 1/4" aluminum rivets every 12".
  The walls will be insulated with pink rigid insulation, 1/2" plywood and then FRP in all areas but the 6' hood.  Behind the hot appliances will be stainless steel with no plywood and no insulation.
Ceiling will be fiberglass insulation with FRP.

Next project...frame the new window, 8'x3', and install the studs on the service side.
 
Removed the ceiling.  I thought it smelled off when pulling it down, found lots of mouse droppings.  And to think it used to be a bread truck.....
 

<message edited by BelCibo on Sat, 12/22/12 2:03 PM>

BelCibo
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Re:Food Truck Build 1979 P60 - Sat, 12/22/12 1:55 PM
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Proposed Layout:
 
We are not required to have a commissary here in Idaho as long as you have a full service truck.  Since we will be prepping veggies and fruit it requires a vegetable sink, so five sinks total.
The hot side has a counter depth of 30", the service side is 21".
The window location is defined by the line at the bottom of the drawing.  it had to stay that far left since a hole had already been cut for the existing 4' window.
 
We have not submitted plans to the HD yet but I need to within the next couple weeks.


BelCibo
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Re:Food Truck Build 1979 P60 - Mon, 12/24/12 6:48 PM
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[This post was marked as helpful]
Got the new window in today.

 


BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 12/28/12 11:15 AM
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Question for you guys on interior light placement.
 
My thought was to put the lights, 4' T8's, directly above the work surfaces.  I realize this will force me to use safety coated bulbs. This in theory is to prevent shadows on the work surface and to keep someone from hitting their head on the fixtures if they were in the center.  I'm 6'2" and the ceiling is 6'6" without installing the flooring.
 
Any comments on doing it this way?  My electrical is going to be inside the walls/ceiling so I only get one shot at light placement.

chefbuba
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Re:Food Truck Build 1979 P60 - Fri, 12/28/12 1:20 PM
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I have three4' lights down the center and one across the nose over the sinks, also two 100 watt bulbs in the hood, plenty of light, no shadows.
Do you need to have your build inspected for mechanical?
We have labor & industries (building inspector) here in WA, they inspect all plumbing, mechanical, electrical. My electrical was required to be surface mounted.
Better check before you do any work and get that hd approval.

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 12/28/12 1:49 PM
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chefbuba


I have three4' lights down the center and one across the nose over the sinks, also two 100 watt bulbs in the hood, plenty of light, no shadows.
Do you need to have your build inspected for mechanical?
We have labor & industries (building inspector) here in WA, they inspect all plumbing, mechanical, electrical. My electrical was required to be surface mounted.
Better check before you do any work and get that hd approval.

 
Thanks for the response, was kinda getting ahead of myself there.
I contacted our county and the state of Idaho building department and apparently there are no requirements aside from the HD on mobile units.  As long as everything is within the truck and not permanently attached to outside water or power they have no requirements.  I got the impression it was not a normal question as I got routed through three different people. 

chasendad
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Re:Food Truck Build 1979 P60 - Fri, 12/28/12 6:49 PM
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I was looking at you layout, they allow you to have toilet on your truck? That just seems a little to close to the food for me..lol

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 12/28/12 7:48 PM
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chasendad


I was looking at you layout, they allow you to have toilet on your truck? That just seems a little to close to the food for me..lol

 
I spoke with the HD about it and they had no issue as long as it is a separate room, the door was tight fitting and it had a ventilation fan.  If we end up with a bathroom it would just have a self contained toilet inside.  If we were in an area it was not allowed or there were public restrooms close we could just remove the toilet and use it as storage.  Not 100% sold on the idea yet.  My wife will be running the truck during lunch alone, that's the main reason.

BelCibo
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Re:Food Truck Build 1979 P60 - Mon, 12/31/12 2:46 PM
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Anyone have some ideas about what to do with the gas tank door? It is under a door behind where the passenger seat would be. I would really like to extend the filler neck and move to the outside but the pocket door is in the way.  If I move it behind the pocket door that is the location of the tankless water heater exit vent....Boom.
 

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 01/4/13 4:24 PM
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Question for you guys.  Is there something creative that can be done for sink drain boards?  The board above the sink attached to the wall, a front mounted shelf that folds down etc?  Trying to reduce the length of the dish wash area.  Without drain boards I can get a pretty nice setup in the 32-38" range, with drain boards I'm looking at another 20". That would only leave me 20" for the hand wash and veggy prep sink.

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 01/4/13 5:09 PM
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Looks like I found my own answer:
 
Idaho Food Code
Drainboards, UTENSIL racks, or tables large enough to accommodate all soiled and cleaned items that may accumulate during hours of operation shall be provided for necessary UTENSIL holding before cleaning and after SANITIZING.
 
I would interpret that as a draining shelf above the first sink for dirty and a shelf above the sanitizing sink for sanitized dishes would work.  This sound reasonable before I speak with the HD?  The guy is gonna hate me if I keep calling him everyday.  Thanks

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 01/4/13 5:32 PM
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chasendad


I was looking at you layout, they allow you to have toilet on your truck? That just seems a little to close to the food for me..lol

 
While researching code in the various cities we plan on going to we found that although a toilet is allowed by the HD, one of the cities (Boise) has additional health requirements. Restrooms cannot open directly into the cooking or prep area.  Looks like the toilet is out of the plan.

chasendad
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Re:Food Truck Build 1979 P60 - Fri, 01/4/13 7:10 PM
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I bought a 48" metro shelf and bracket to put above the sink that works around here..

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/10/13 9:55 PM
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Electrical conduit in and most of the wire pulled.  Here are the electrical boxes I found, they have nice ears to rivet.
 


BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/10/13 10:01 PM
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Hot wall.  Going from back to front, top to bottom:
120v20a circuit 1
120v20a circuit 1
Juntion box that will output MC wire for AC (20a circuit 7), interior and exterior lights (circuit 2).
120v20A circuit 2 
120v20A circuit 2
240V30A circuit 3 
Breaker box is a surface mount 100A with 6 standard slots.  Generator is a 6000w Kipor (50A).  Switch panel will be just below breaker box for interior lights, exterior lights, hood fans, water circuit
 

<message edited by BelCibo on Thu, 01/10/13 10:13 PM>

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/10/13 10:04 PM
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Picture of conduit going into front cab top panel.  This is how wire gets from the breaker box to the other.
 


BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/10/13 10:07 PM
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Service side. 
120v20A circuit 5 This box is switched and will be providing power to water pump and tankless propane heater.
Speaker wire 1
120v20A circuit 4
120v20a circuit 4
 

<message edited by BelCibo on Thu, 01/10/13 10:08 PM>

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/10/13 10:08 PM
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120v20a circuit 6
120v20a circuit 6
 
Exterior lights will be at the top corners of the service window as will the speakers.
 

<message edited by BelCibo on Thu, 01/10/13 10:54 PM>

BelCibo
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Re:Food Truck Build 1979 P60 - Mon, 01/21/13 9:58 AM
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No more progress on the truck, too stinking cold.  It's been below zero in the mornings and only in the teens during the day.
 
On a side note we had 20 people over to test the menu out in our house kitchen this weekend and that went really well.  Passed out feedback sheets a got a few useful comments.
 
Showed my wife how to use some Lean Manufacturing tools and did some process flows.  Knocked her grilled Pastrami down from just over 5 mins to right at 3.
 
Next step is laminating FRP ceiling panels in the house :/

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/31/13 11:52 AM
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Can I get some opinions on sink placement? 
 

With the layout above we would have a cutting board insert that will cover the wash sinks and provide a work surface for fruit and veggy prep.  The hand sink has side guards.
 
Another option would be to swap the Veg and Hand sinks but this moves the Hand wash sink farther away from the main work area. Maybe go with undermount Veg sink and leave a cutting board covering to get counter space back or
 
Install the Hand sink under the Veg sink to save the counter space but my concern is bending over to wash hands constantly.  I'd like to make hand washing as easy as possible so its done consistently.
 
The line at the screen bottom is the window. Comments or other ideas?  Thanks!

reese77
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Re:Food Truck Build 1979 P60 - Thu, 01/31/13 12:11 PM
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The veg sink is required? I think the sink layout looks good. I would probably move the hand sink to the other side of the wash sink but either way.

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 01/31/13 12:28 PM
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If I have a Veg sink we are considered a full service truck and don't have to have a commissary.  We will need to prep fruits and vegetables.
 

reese77
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Re:Food Truck Build 1979 P60 - Thu, 01/31/13 12:31 PM
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WOW! I wish I had that option in GA. Lucky you.

BelCibo
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 2:24 PM
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Got the back door and wall in this weekend.  Door is 36" wide and made by a local RV door manufacture.  Going that wide let me get away with one sheet of aluminum instead of two.  
Used 2" aluminum channel and .050" aluminum sheet with 1/4" rivets.  Rigid foam insulation.

 

Note to self, don't use 2" channel for your back wall as it leaves you no room for the plywood.  The doors are made for 2" walls so use 1 and 1/2" channel with 1/2" ply and it will be flush.
 
The corner brackets on top look like you can take them off and install your sheet underneath.  Well you can't because they have nuts behind them that are boxed in with channel.  Cut the corners to match the radius with an electric shear and siliconed the seam.
 
The steel brackets that hold the original door spring had to be removed so the interior walls fit evenly.  They are welded and would not come off without getting out the 4" grinder.  

reese77
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 3:02 PM
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Looks good, nice work. I need to invest in a TIG welder so I can work with aluminum.

BelCibo
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 8:14 PM
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The HD approved my plans today.  Next check is two weeks prior to open.

reese77
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 8:36 PM
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So you were able to submit your plans for approval w/o a commissary? Or do you already have the commissary?

BelCibo
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 8:48 PM
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Correct, no commissary required!

buffy1711
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 9:38 PM
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You were able to start construction before HD approval?

BelCibo
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Re:Food Truck Build 1979 P60 - Wed, 02/20/13 11:13 PM
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I did start without approval, risking having to change something if they didn't approve.  The code specifically says you must get approval before starting construction, I was bad.

buffy1711
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Re:Food Truck Build 1979 P60 - Thu, 02/21/13 9:34 AM
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Lol, I see. Here there is a strict rule, if you get caught building before approval, you will be shut down. I didn't touch my truck until the day I was approved. What about the commissary? What are some things that are required on the truck to make that possible? Here in Michigan there are certain things the truck must have, like a mop sink. You have to basically be a self contained unit. Are there requirements? Just curious.

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 02/21/13 9:51 AM
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The requirements are specific to Mobile Units, if the unit is Full Service, no commissary is needed.  To be considered "Full Service" it has to have a prep sink if washing of vegetables is required.    A mop sink is required per the code but not on a Mobile Unit according to our Health Inspector.  From reading on this forum, Idaho rules are much more relaxed than elsewhere. 
<message edited by BelCibo on Thu, 02/21/13 9:53 AM>

a.mckenna
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Re:Food Truck Build 1979 P60 - Thu, 02/21/13 11:39 AM
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BelCibo, send me a email at alice.mckenna1 at gmail dot com.
 
I built a trailer for someone who planned on operating in Northern Idaho, Sand Point area. This was a very low budget job and the cart reflect that, but it still passed with flying colors. Might be able to save yourself some money looking at these pictures. Overkill is totally not necessary in Idaho.
 
In reference to the electric questions earlier in this thread. I mount all electric exposed and run MC cable. One, health departments LOVE when things are visible, two it is easier to make repairs or additions on and requires minimal downtown for doing so.
 
As far as starting prior to approval. I never get approval, and have passed carts in 5 states lol.

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 12:28 AM
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Exterior lights, speakers, and awning installed. Lights are the 20w multicolor LEDs, they look pretty cool at night.

<message edited by BelCibo on Fri, 02/22/13 12:30 AM>

daddywoofdawg
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 1:58 AM
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Where did you get your lights?I need some ext. ones.What is MC wire?As far as approval you can start you just don't tell the HD you did.and you do risk having to do over that way.
Here In ND 3sinks,+handwash,fire ext,light colored floors,and test strips and your golden.But when the come to inspect they are all over food temps.
Anyone intrested, if I start a post of some of the rules in my state, others chime in with what you need in their state and maybe we can make a sticky.
<message edited by daddywoofdawg on Fri, 02/22/13 2:01 AM>

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 7:53 AM
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MC Wire

Got my lights off Ebay, Amazon has them as well.  After seeing them I would not recommend the 10W version unless it is for a menu board or something smaller.  If I get the time I'll get a nighttime picture of them.  They have 16 colors, can fade between them as well.  After the graphics get installed we'll find a color that pops and stick with that.
http://www.ebay.com/itm/V...mp;hash=item2a25d22e10
 
When I asked our HD guy what were the biggest reasons for failing the initial inspection he said 1) Not using commercial equipment, and 2) not finishing surfaces i.e. unpainted wood, rough surfaces and gaps.
 
<message edited by BelCibo on Fri, 02/22/13 7:59 AM>

chefbuba
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 10:18 AM
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MC Cable will be a bitch to keep clean.

buffy1711
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 10:58 AM
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Where did you get the cutting board insert for your sink? I've looked many places and they are very expensive. I have a full sink in my truck and need more workable space. Any ideas?

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 1:32 PM
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buffy1711


Where did you get the cutting board insert for your sink? I've looked many places and they are very expensive. I have a full sink in my truck and need more workable space. Any ideas?

 
I have not purchased mine yet.  Find a local plastic supplier and buy direct.  Interstate Plastics is a big one.  Online a custom cut 20x34 sheet is around $90 with shipping.
http://www.interstateplas...0&recalculate.y=16
 

a.mckenna
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Re:Food Truck Build 1979 P60 - Fri, 02/22/13 1:38 PM
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chefbuba


MC Cable will be a bitch to keep clean.

Not if it is run right and you keep your trunks (bunches of wire) in areas away from greasy equipment, or mounted below counter level so it is not directly visible.

BelCibo
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 10:48 AM
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Worked on the generator access this weekend.  The genny was too tall to fit underneath so it is 1/2 in and 1/2 out. Layout dictated the location on the truck. It will be bolted to a shelf that slides in and out on a 500lb drawer slide.  Hinge will be in the front edge of the hole, not the top.  Framed the sides in with steel angle, you will see some of it in the picture but it's not done.  Will box in the area under truck to keep it clean.  Will spray with bedliner as well.
 
Theory of operation will be to pull into location, open door and secure.  Run Genny.  If space allows, slide the genny out so it is completely free air.  Will probably install a 120v fan as well to keep her cool.





BTM676
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 2:18 PM
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Hey. Where did u get ur awning from? Great looking truck by the way!

BelCibo
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 5:43 PM
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Awning was from these guys:
http://www.ebay.com/itm/G...mp;hash=item43b0089ce8
 
Mine no longer has the valance, it's on the highway somewhere after the first road trip.

BelCibo
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 7:48 PM
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Floor is in, most of the walls inside except behind appliances.  Genny box done.  Next steps are finish the genny drawer slides and exterior door, FRP walls and ceiling. Really need my hood as it affects the FRP position, ceiling lights etc, ordered last week so 1-2 weeks wait.



<message edited by BelCibo on Sun, 03/3/13 7:51 PM>

BelCibo
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 8:48 PM
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Awning Pictures




BTM676
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 11:30 PM
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Did all the hardware come with the awning or did you have to make brackets to mount it? Thanks BelCibo.

BelCibo
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Re:Food Truck Build 1979 P60 - Sun, 03/3/13 11:49 PM
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BTM676


Did all the hardware come with the awning or did you have to make brackets to mount it? Thanks BelCibo.

 
That's the hardware it came with, basic but a good match for a food truck.

BelCibo
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Re:Food Truck Build 1979 P60 - Mon, 03/4/13 12:00 AM
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Now keep in mind I've only used it in the driveway.  It looks sturdy but it has not stood the test of time.

Dr of BBQ
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Re:Food Truck Build 1979 P60 - Mon, 03/4/13 8:22 AM
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a.mckenna
chefbuba
MC Cable will be a bitch to keep clean.


Not if it is run right and you keep your trunks (bunches of wire) in areas away from greasy equipment, or mounted below counter level so it is not directly visible.

 
I'm afraid Chef Buba is correct, and I have had numerous health department inspectors get on their hands and knees and remove all my extra steam table pans, and bulk condiment containers on a lower shelf in order to get a better view of the conduit and wall below my counters. Fortunately I'm a clean freak and we keep it very clean, but it takes a lot of time and labor. But just plain conduit is a PITA to keep really clean when attached to the wall. The area directly behind conduit is a perfect catch all for grease, dust and debris. The flex conduit will just be more of a hassle. Sorry. 

BelCibo
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Re:Food Truck Build 1979 P60 - Thu, 03/7/13 9:22 PM
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Solution to the inside gas door issue:
Before

After: Marine Deck plate
http://www.amazon.com/gp/..._i00?ie=UTF8&psc=1


<message edited by BelCibo on Thu, 03/7/13 9:24 PM>

Kokomo_Sno
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Re:Food Truck Build 1979 P60 - Fri, 03/8/13 3:00 AM
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Very nice build you have going on. Maybe I'll see it in person when you're up and running.

evanjohnson
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Re:Food Truck Build 1979 P60 - Mon, 03/11/13 2:28 PM
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BelCibo


If I have a Veg sink we are considered a full service truck and don't have to have a commissary.  We will need to prep fruits and vegetables.


 
Where do you have to dump your grey water?


BelCibo
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Re:Food Truck Build 1979 P60 - Mon, 03/11/13 2:39 PM
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evanjohnson


BelCibo


If I have a Veg sink we are considered a full service truck and don't have to have a commissary.  We will need to prep fruits and vegetables.



Where do you have to dump your grey water?

 
 I will be using an RV dump station that's within a mile of home.  I don't remember the exact wording but it has to be an approved dump site.

BelCibo
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Re:Food Truck Build 1979 P60 - Wed, 03/13/13 11:45 PM
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I'm headed to Houston for a week on business, any food trucks or eateries I just have to visit?

daddywoofdawg
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Re:Food Truck Build 1979 P60 - Fri, 03/15/13 10:55 PM
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You may want to move those speaker wires away from the power wires.the speaker will pick up a hum next to the wires when there is power.

BelCibo
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Re:Food Truck Build 1979 P60 - Fri, 03/29/13 8:19 AM
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FRP going up.
 

<message edited by BelCibo on Fri, 03/29/13 8:22 AM>

BelCibo
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Re:Food Truck Build 1979 P60 - Tue, 04/2/13 10:30 AM
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All the FRP is now installed, ceiling up, stainless back wall finished.  Still need to finish the trim work.
 
Installed the hood.  8 Footer from Superior Hoods.  Installed per their instructions with 3/8 threaded rod, used nylon lock nuts so they can't back out with 2x2x2 aluminum channel on the roof.
 
Gap at the top to be filled in after I finish the wall fan install.

 
<message edited by BelCibo on Tue, 04/2/13 10:32 AM>

chasendad
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Re:Food Truck Build 1979 P60 - Sat, 04/6/13 7:29 AM
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Can I ask what size is the hood and what did it cost?? Looking for another supplier..

BelCibo
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Re:Food Truck Build 1979 P60 - Sat, 04/6/13 11:00 PM
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The hood is 8 foot made by Superior. 24 x 30 with a 4" front lip.  All stainless construction except for aluminum filters.  I got it from A City Discount for $1560 shipped, the lights were an adder.  They have a 10% off code, 12hoods10. Quality is descent, I think the Captive Air was a little nicer hood but the front was taller and they didn't make it without a 3" backwall spacer.
 
http://www.acitydiscount.com/Superior-Hoods-8-Ft-Stainless-Steel-Concession-Range-Grease-Hood-NSF-NFPA96-CS30-4-96.0.60258.1.1.htm

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