Helpful ReplyHot!Food Truck Build 1979 P60

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BelCibo
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2012/12/22 13:27:22 (permalink)

Food Truck Build 1979 P60

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

 

post edited by BelCibo - 2012/12/23 10:02:37
#1
BelCibo
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Re:Food Truck Build 1979 P60 2012/12/22 13:41:21 (permalink)
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.....
 

post edited by BelCibo - 2012/12/22 14:03:09
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BelCibo
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Re:Food Truck Build 1979 P60 2012/12/22 13:55:58 (permalink)
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.

#3
BelCibo
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Re:Food Truck Build 1979 P60 2012/12/24 18:48:08 (permalink) ☄ Helpful
Got the new window in today.

 

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BelCibo
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Re:Food Truck Build 1979 P60 2012/12/28 11:15:09 (permalink)
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.
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chefbuba
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Re:Food Truck Build 1979 P60 2012/12/28 13:20:40 (permalink)
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.
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BelCibo
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Re:Food Truck Build 1979 P60 2012/12/28 13:49:17 (permalink)
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. 
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chasendad
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Re:Food Truck Build 1979 P60 2012/12/28 18:49:59 (permalink)
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
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BelCibo
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Re:Food Truck Build 1979 P60 2012/12/28 19:48:35 (permalink)
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.
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BelCibo
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Re:Food Truck Build 1979 P60 2012/12/31 14:46:35 (permalink)
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.
 
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/04 16:24:37 (permalink)
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.
#11
BelCibo
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Re:Food Truck Build 1979 P60 2013/01/04 17:09:47 (permalink)
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
#12
BelCibo
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Re:Food Truck Build 1979 P60 2013/01/04 17:32:25 (permalink)
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.
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chasendad
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Re:Food Truck Build 1979 P60 2013/01/04 19:10:22 (permalink)
I bought a 48" metro shelf and bracket to put above the sink that works around here..
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/10 21:55:47 (permalink)
Electrical conduit in and most of the wire pulled.  Here are the electrical boxes I found, they have nice ears to rivet.
 

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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/10 22:01:18 (permalink)
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
 

post edited by BelCibo - 2013/01/10 22:13:02
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/10 22:04:29 (permalink)
Picture of conduit going into front cab top panel.  This is how wire gets from the breaker box to the other.
 

#17
BelCibo
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Re:Food Truck Build 1979 P60 2013/01/10 22:07:19 (permalink)
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
 

post edited by BelCibo - 2013/01/10 22:08:50
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/10 22:08:31 (permalink)
120v20a circuit 6
120v20a circuit 6
 
Exterior lights will be at the top corners of the service window as will the speakers.
 

post edited by BelCibo - 2013/01/10 22:54:33
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/21 09:58:45 (permalink)
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 :/
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/31 11:52:21 (permalink)
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!
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reese77
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Re:Food Truck Build 1979 P60 2013/01/31 12:11:55 (permalink)
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.
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BelCibo
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Re:Food Truck Build 1979 P60 2013/01/31 12:28:21 (permalink)
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.
 
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reese77
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Re:Food Truck Build 1979 P60 2013/01/31 12:31:52 (permalink)
WOW! I wish I had that option in GA. Lucky you.
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BelCibo
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Re:Food Truck Build 1979 P60 2013/02/20 14:24:04 (permalink)
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.  
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reese77
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Re:Food Truck Build 1979 P60 2013/02/20 15:02:20 (permalink)
Looks good, nice work. I need to invest in a TIG welder so I can work with aluminum.
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BelCibo
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Re:Food Truck Build 1979 P60 2013/02/20 20:14:52 (permalink)
The HD approved my plans today.  Next check is two weeks prior to open.
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reese77
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Re:Food Truck Build 1979 P60 2013/02/20 20:36:47 (permalink)
So you were able to submit your plans for approval w/o a commissary? Or do you already have the commissary?
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BelCibo
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Re:Food Truck Build 1979 P60 2013/02/20 20:48:46 (permalink)
Correct, no commissary required!
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buffy1711
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Re:Food Truck Build 1979 P60 2013/02/20 21:38:06 (permalink)
You were able to start construction before HD approval?
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