What a great story. I think that's one of the big things that's hard to grasp about the US is that it's HUGE and the entire infrastructure is built towards cars.
How long did it take you to finish the van? Did you finish everything at one time or was it over the course of your trip?
from the moment we bought the wood maybe two days later we had the bed, windows and light done... me mattress maybe toke us another full day to find... i think in 4 days we had it ready with drowers, boxes and all... the mechanics we did when needed :)